Wire and Cable - IS-Rayfast Literature...Introduction 9-2 Wire and Cable Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional
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9Wire and Cable
9-1
Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Note: Users should independentlyevaluate the suitability of theproduct for their application.Before ordering, check withTE Connectivity for most current data.
Introduction
9-2
Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
TE provides wire and cablesolutions for challengingenvironments and demandingapplications. The productrange includes high-per-formance insulated wires,coaxial and data buscables, power cables, electronics wire, and multi-core cables.
n SPEC 44 wire is an economical yet ruggeddual-wall insulation system rated at 150°C[221°F], with consistentlylow cost and reliable performance.
n SPEC 55 wire insulationprovides high reliability in harsh environmentsfrom -65°C to +200°C[-85°F to +392°F].Resistant to electrical arc tracking, it combinesthe easy handling of aflexible wire with excellentresistance to scrape abra-sion, and cut-through.
n SPEC 80 (FlexLine) wireis insulated with a flexiblemodified radiation cross-linked ETFE polymer witha temperature rating of -65˚C to +200˚C [-85˚F to-395˚F]
n Type 99 wire has a dualwall construction and hasexcellent mechanical per-formance and chemicalresistance with a range ofenhanced fire hazardproperties.
n ElectroLoss Filterlinewire reduces the vulnera-bility of critical circuits to high-frequency electro-magnetic interference.
n Cheminax coaxial anddata bus cables allowsystem designers to optimize minimum sizeand weight with imped-ance and attenuation characteristics.
n Multiconductor (multi-core) cables organize avariety of TE wire andcable products in con-trolled geometries for specific applications.
Using a computer-aideddesign system, TE canquickly design multicorecables to meet yourneeds. A variety of cablejackets are available tosuit most applications.
n High Speed Coppercable designs are avail-able for Cat 5e, Cat 6,IEEE 1394 and USB appli-cations. This family ofcables can be cus-tomized to meet specificapplication needs.
n SeaLAN Cat 5e andZerohal PROFIBUScables are designed to be used in the demandingmarine environmentalconditions while still meeting the high perform-ance data standards.
n Quadlite quadraxialcables, rated up to 200˚C,offer small size and lightweight high speed solutions in aerospaceapplications which require data protocolssuch as 100BaseT,1000BaseT, FiberChanneland IEEE 1394.
n C-Lite low fire hazardlightweight cables offersignificant size andweight reduction, whencompared to conventionalinsulation systems, whileat the same time meetingkey criteria such as lowfire hazard performanceand mechanical robustness.
n FlexLite commercialwire family is available in various constructions for a variety of applicationswith temperature ratingsfrom -45˚C up to 250˚C. FLCW is a general purpose and motor lead wire.FLDW is a dual-wall primary wire.FLTW is a thin-wallhookup wire and cable.FLHT is a high-tempera-ture hookup wire.FLTX is an ultra-high temperature hookup wire.
TE wire and cable productscan meet your specificapplication needs. Here arejust a few examples:
n Limited-fire-hazard wireand cable for mass transitand marine applications.
n High-performance, hightemperature automotivewiring.
n Small, light hookup wiresfor high-temperatureapplications in commercialappliances, tools, anddevices.
n Very flexible, rugged, thin-wall insulated powercables.
n Low-outgassing space-vehicle wiring.
n Lightweight, shielded wireand cable constructionsfor aerospace applications.
n Thermocouple extensioncables with a range of our high-performanceinsulation materials.
Contact TE to find out moreabout wire and cable andour associated interconnec-tion products.
SPEC 44
9Wire and Cable
9-3
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Applications
SPEC 44 wire has a dualwall construction whichcombines the outstandingphysical and electricalcharacteristics of radiationcrosslinked polyalkene withthe excellent mechanicaland chemical properties ofradiation cross-linkedpolyvinylidene fluoride(PVDF).
The result is a wire insula-tion system that offers a150°C [302°F] temperaturerating, small size, lightweight, solder iron resist-ance, and resistance tomost solvents, fuels andlubricants.
SPEC 44 wire and cable ishighly flame retardant, non-melting, does not cold flow,
and though mechanicallyvery tough, is easy to han-dle and install using con-ventional tools.
Originally developed foraerospace and militaryrequirements in applica-tions of high density andcomplex circuitry, SPEC 44wire and cable now findswide use throughout indus-try, in commercial and military electronics, avionics, on satellites, aircraft, helicopters, ships,trains, military ground systems, and offshore plat-forms where environmentalconditions demand consis-tently reliable performance.In airframe applicationsSPEC 44 constructions can
Product Factsn Dual wall constructionn 600, 1000 and 2500 voltagerating
n Small size, light weightn Resistant to most chemicalsand electrical arc tracking
offer a modern dimensionalreplacement for PVC/Nylon/Glass braid type wire andcables. SPEC 44 wire isoffered in a wide range ofsizes in stranded conduc-tors, standard materialsavailable being tin or silver-plated copper andhigh strength copper alloy.Voltage ratings of 600, 1000and 2500 volts are availableas standard. Shielded andjacketed versions includesingle and multi-conductorconstructions and flat braidshields where further sizeand weight savings areachieved.
Available in: Americas Europe Asia Pacific
n n n
9-4
SPEC 44 (Continued)
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Physical Characteristics
Small Size
SPEC 44 equipment wire,600 volt rated has a 0.19[.008] nominal wall thick-ness compared to 0.25[.010] and 0.38 [.015] forequivalent PTFE and PVCwires in MIL-DTL-16878,SAE AS22759 or BS 3G210.
Light Weight
Because of the thin wall andlow density of the insulationmaterials considerableweight savings are madeover similarly rated PTFEwires, eg:- 44A0111-22AWGequipment wire 4.45grams/meter max22 AWG PTFE equipmentwire, AS-810445.54 grams/meter max
General Handling
The flexibility of SPEC 44and the ease with which ittakes a 'set' makes it one ofthe easiest of the 'high performance' wires toinstall. Stripping is donewith conventional die bladestrippers.
The tin-plated conductorusually specified is easilysoldered or crimped. Theinsulation may be easilyprinted and does not needetching before potting.
Specifications/ApprovalsAS-81044, NEMA-WC-27500 (Cables)Def Stan. 61-12 Part 18 - Type 1 pliable (Maintenance Range)Def Stan. 61-12 Part 26 All typesVG 95218 Parts 20, 21, 22, 23 and 1000NATO Stock Numbers (NSN's) exist for most standard constructionsCivil Aviation Authority Accessory Approval E11623TE Specification 44
Typical PropertiesTemperature rating -65°C to +150°C [-85°F to +302°F]Voltage rating (thin wall) 600 VVoltage rating (thick wall) 2500 VTensile strength and elongation of insulation 28 N/mm2, (4000 PSI), 230%Notch propagation, 0.05mm notch PassSolder iron resistance (370°C, 1 minute) PassShrinkage, 300°C <1%Low temperature bend -65°C [-85°F]Voltage withstand (thin wall) 2500 VResistance: fuels, oils, solvents Pass
Lengths
SPEC 44 is available in longcontinuous lengths and canbe supplied for use on auto-matic cut and strip wirepreparation machines.
NOTE:Please check with TE personnel to ensure the product you wish to purchase is manufatured and released to thespecification required.
9Wire and Cable
9-5
SPEC 44 (Continued)
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Environmental Performance Temperature Rating
SPEC 44 wire and cable israted for continuous opera-tion from -65°C to +150°C [-85°F to +302°F] and forshort periods at tempera-tures as high as 300°C[572°F]. Heat ageing testsare routinely performed attemperatures of 200°C[392°F] (168 hr) and 300°C[572°F] (6 hr). In additionSPEC 44 insulation will notshrink back under repeatedcycling.
Mechanical Performance
SPEC 44 wire provides bet-ter cut through resistancethan some wires with muchthicker walls. 600 volt equip-ment wire 44A0111 (0.19mm wall) has 40% greatercut through resistance than600 volt PTFE insulated wire(0.25 mm wall).
Solder Iron/OverloadResistance
The radiation crosslinking of the materials used in SPEC 44 makes them non-melting at high temperature.As a result SPEC 44 wire isresistant to prolonged con-tact with solder irons and isresistant to current over-loads which would melt mostthermoplastic insulation.
Chemical Resistance
The irradiated dual wallconstruction of SPEC 44wire is highly resistant tomany acids, alkalis, hydro-carbon solvents, fuels, lubri-cants, water, and many missile fuels and oxidizers.
Cold Flow
Radiation cross-linking ofSPEC 44 prevents cold flowof the insulation — a recog-nized problem of someuncrosslinked materials.
Voltage Ratings
Standard available voltageratings for SPEC 44 wire are600 volts (0.19 mm wallthickness), 1000 volts (0.28mm wall) and 2500 volts(0.48 mm wall).
Electrical Arc Track Resistance
SPEC 44 insulation demon-strates a resistance to arctracking under both wet anddry conditions at aircraftsystem voltages.
Low Outgassing
For use in space applica-tions, special constructionsof SPEC 44 wire are avail-able with low outgassingcharacteristics, for use in anenvironment of high vacuumand high temperature.
Federal Aviation Reg FAR-25 PassBS EN 50265 Vertical Flammability Pass
Flammability S424 14751 (Swedish chimney) PassNFC 32070 (2) (French chimney) PassIEC 60332 part 3 (Cable ladder) PassSmoke Index, Def Stan 61-12 (18) 6 per meter of wire
Smoke/Toxicity IndexToxicity Index, Def Stan 61-12 (18) 0.8 per meter of wireBS EN 1S0-4589 Part 2 30% OxygenBS EN 1S0-4589 Part 3Temperature Index, NES 715 >300°C [572°F]
Fire Hazard Performance
* Classes 4, 5 and 6 available only as “44/” constructions. 44/7xxx and 44A7xxx will be available as indicated on the applicable SCD. **Shield coating same as conductor coating except: - for Conductor Type 4, 6, C and D, shield shall be tin-coated copper for standard products
Typical ordering example 3 conductors, brown, yellow with green stripe, blue, white jacket. If 600 volt, round braid, 20 AWG tinned conductor, 44A1131-20-1/45/6-9.
Ordering information Other constructions and custom designed wire and cable are available on request.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-6
SPEC 44 (Continued)
High Performance Wire and Cable
44 X X X X X- AWG- X/X- X
Basic Product Number
Construction0 - Primary wire; or unshielded & unjacketed cable1 - Round braid shielded and jacketed cable**2 - Tin-coated copper flat braid shielded & jacketed cable3 - Round braid shielded cable, no jacket**4 - Jacketed cable, no shield5 - Spiral braid shielded & jacketed cable**7-9 - Special constructions
Temperature Rating:/ - 135˚C (XL-PVF2 cable jacket) - USA only A - 150˚C (XL-PVF2 cable jacket) AC - 150˚C (same as 44AM with 90% min. shield coverage)AM - 150˚C (M27500, shielded and/or XL-PVF2 jacketed cable)B - 150˚C (XL-ETFE cable jacket)D - 135˚C (XL-PVF2) - Def Stan Part 26-UK only)
Class of Wire1 - 600 volt, general purpose 6 - 2500 volt, outerspace*2 - 1000 volt, general purpose 7 - 600 volt, airframe3 - 2500 volt, general purpose 8 - 600 volt, medium weight4 - 600 volt, outerspace*5 - 1000 volt, outerspace*
Number of Conductors1 through 10 (designator for 10 conductor = 0)
Conductor Size (AWG)
Conductor Type1 - Tin-coated copper A - Silver-coated CS95 2 - Silver-coated copper C - Silver-coated high strength3 - Nickel-coated copper copper alloy (cadmium-free)4 - Silver-coated high strength D - Nickel-coated high strength copper alloy copper alloy (cadmium-free)5 - Aluminum6 - Nickel-coated high strength copper alloy
Primary Wire Insulation Color(code per MIL-STD-681) 0 - Black 5 - Green1 - Brown 6 - Blue2 - Red 7 - Violet3 - Orange 8 - Gray4 - Yellow 9 - White
Jacket Color (codes same as for Primary Wire Insulation Color)
Part Numbering System Cross items that arenot standard.
Part Numbering System is across reference only and notmeant for part creation.
SPEC 44 (Continued)
9Wire and Cable
9-7
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Basic Specification Number
Component Wire ID/Shield Coverage Code Shield Coverage 85% 90% Component Wire Identification - C Colored Stripes on White Wire (9/96/93/95/92/90/94/97/98/91... etc.) A D Solid Color Wires (9/6/3/5/2/0/4/7/8/1...etc.) B E Band Marks on Solid Colors (by AWG) F H Alternate Colored Stripes (92/96/94/95/9/90/91/93/97/98...etc) G J Alternate Solid Colors (2/6/4/5/9/0/1/3/7/8...etc.) K M Number Marking on Solid Colors (by AWG) L N Number Marking on White Wires P R Band Marks on Colored Stripes (by AWG) S T Band Marks on White Wires U V Non-standard color - defined by customer
Other sizes are also available in some constructions depending on conductor type and construction required.
Shielded and JacketedCable
44A111X (600 V)1 Conductor
44A121X (1000 V)1 Conductor
SPEC 55
9-10
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Applications
SPEC 55 wire is insulatedwith modified radiationcross-linked ETFE polymer.It has a temperature ratingof -65°C to 200°C [-85°F to392°F] continuous using asilver plated copper con-ductor, and combines theeasy handling of a flexiblewire with excellent scrapeabrasion and cut-throughcharacteristics.
The dual wall airframe con-struction of SPEC 55 wire iscurrently used on numerousaircraft programs. It has achoice of two total wallthicknesses, 0.25 [.010](55A08XX 10 mil) and 0.2[.008] (55A02XX 8 mil).Both have a contrastingcore color to act as a dam-age indicator. Chosen for itsbalance of properties, SPEC 55 wire has outstand-ing resistance to chemicalsand solvents, excellentelectrical arc track resist-ance, and is not susceptibleto UV and moisture degra-dation. Single wall equip-ment wire constructions are available in 0.10 [.004](55/03XX 4 mil) and 0.15[.006] (6 mil) wall thicknessesfor use inside black boxeswhere flexibility and solder-iron resistance make it awire which is very easy toinstall reliably.
Both single and dual wallinsulated wires are available
in twisted pairs, triples, etc.,and as shielded and jacket-ed cables.
Physical Characteristics
Size and Weight
SPEC 55 wire provides oneof the most comprehensivewiring product ranges foraerospace users, with awide choice of conductorsizes and insulation wallthicknesses.The dual wallairframe wire has an insula-tion wall thickness of either0.2 [.008] or 0.25 [.010] forrobustness in unprotectedharnesses and has excel-lent wire to wire abrasionproperties.
The single wall equipmentwire has a 0.15 [.006] wallthickness for use insideequipment and protectedharnesses. For high density,interconnect wiring, the 450volt 55M041X series ofequipment wire has a nomi-nal 0.1 [.004] wall and pro-vides considerable weightand size savings over othercomparable wires.
Handling
The excellent flexibility and handleability makes SPEC 55 the ideal wire toinstall, both in new aircraftand equipment and formaintenance purposes. Thewire is easily stripped withconventional tooling. Theinsulation is readily marked
by hot stamp, ink jet or laser,and can be potted withoutpre-etching.
SPEC 55PC Wire andCable Insulation System
This product was originallydeveloped to meet Boeing’smaterial standard BMS13-48 for the 777 airliner. SPEC 55PC provides light-weight, compact insulationthat matches the provenperformance of our SPEC 55 wire. Today, 55PCis specified and utilized onthe majority of aerospaceplatforms worldwide.
TE’s rigorous, statistical-process-controlled manu-facturing has producedwiring that is rugged andversatile enough for a widerange of commercial anddefense aerospace applica-tions, including electronichook-ups in harsh, open air-frame environments.
SPEC 55PC wire and cablesystems feature an 8-mil air-frame wire that is lighter andsmaller than typical 10-milwire, with little reduction inkey mechanical perform-ance features. SPEC 55PCwire offers flame resistancesuperior to FAA standardsand also resists scrapeabrasion, notch, propaga-tion, cut-through, and electrical arc tracking.
n Meets Boeing materialstandard BMS 13-48.
n Exceeds FAR 25 testrequirements for flameresistance and smokedensity.
Product Factsn Resistant to electrical arctracking in wet or dryconditions
n Single or dual wallconstructions
n Small size, ultra light weightn Exceptional chemicalresistance
n -65°C to 200°C [-85°F to392°F]
Available in:Americas n
Europe n
Asia Pacific n
SPEC 55 (Continued)
9Wire and Cable
9-11
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
SpecificationsConductor
Insulations -Radiation Crosslinked, Modified ETFEInner layer colored blue
Conductor
Insulation - Radiation Crosslinked, Modified ETFE
SPEC 55 Insulation System - Single Wall SPEC 55 Insulation System - Dual Wall
SAE AS22759/32-35 and /41 to /46 and NEMA-WC-27500 (Cables)Defense Standard 61-12 Part 33 Issue 5Part 1001 and Part 1002VDE 9426, 9427, 9428British Standard 3G233Boeing BMS 13-48Airbus ABS 0820 to 0826NASA preferred product listEuropean Space Agency 3901/012, 3901/020 and 3901/022TE Specification 55Civil Aviation Authority Accessory Approval E11623
Typical Properties Temperature rating (Tin plated conductor) -65°C to +150°C [-85°F to +302°F](Silver or nickel plated conductor) -65°C to +200°C [-85°F to +392°F]
Thermal endurance 200 °C [392°F], 10000 hScrape abrasion (BS 3G233) >100 cycles at 150°C [302°F]Flexing endurance (Boeing BSS 7324) >1000 cyclesVoltage rating 600 V, 1000VTensile strength + elongation (core only) (Dual wall wire) 35 N/mm2, 125% min.Tensile strength + total elongation (core & primary jacket) (Dual wall wire) 35 N/mm2, 75% min.Notch propagation BS 3G230 0.05 mm notch PassSolder iron resistance (370 °C, 1 minute) PassSolderability - Tin plated copper conductor <0.8 secs to wet
BS 3G233 conditionsShrinkage <1%Long term water resistance Will not hydrolyzePermitivity 1 KHz (ASTM D150) 2.7Dissipation factor (ASTM D150) 0.001FAR 25 OAfterburn (sec) 30 sec. max.Burn length 75 mm [3 in.] max.
NOTE:Please check with TE personnel to ensure the product you wish to purchase is manufatured and released to thespecification required.
SPEC 55 (Continued)
9-12
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Environmental Performance Temperature Rating
SPEC 55 wire and cable israted for continuous opera-tion from -65°C to +200°C[-85°F to +392°F] and forshort periods at tempera-tures as high as 400°C[752°F].
Mechanical Performance
Radiation crosslinking of theSPEC 55 insulation signifi-cantly improves the follow-ing mechanical character-istics; scrape (sharpedges), cross wire abrasion,cut-through resistance andcreep resistance.
Solder Iron/OverloadResistance
Radiation crosslinkingensures that the insulationresists melting at high temperatures. As a resultSPEC 55 wire is resistant tohot solder irons and currentoverloads which would meltmost thermoplastic insulation.
Chemical Resistance
SPEC 55 is unaffected by allcommonly used chemicals,eg. fuels, hydraulic fluids, defluxing agents,cleaners, coolants and de-icers. It also showsexcellent resistance toweathering (UV, ozone, pollutants, water).
Space Wire
SPEC 55 is available in special versions suitable for use in outer space meeting both ESA andNASA requirements for outgassing.
Flammability
Special additives increasethe flame retardance ofSPEC 55 compared to unirradiated ETFE so that it meets the latest high performance tests, eg. BS 3G230 and vertical testFAR25.
Electrical Arc TrackingResistance
SPEC 55 insulation demonstrates resistanceto arc tracking under bothwet and dry conditions ataircraft system voltages.
55PC - Extra Light Weight ConstructionsFor applications where weight is critical, light weight tight tolerance conductors and insulation are available. These aremanufactured using statistical process control methods and achieve weights that are equal or lighter than theequivalent polyimide/PTFE constructions.
SPEC 55 Wire & Cable:Standard Constructions,Nominal Sizes, Strandings,Diameters and Weights
SPEC 55 (Continued)
9Wire and Cable
9-13
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Jacket Color (code per MIL-STD-681)Codes same as for Primary Wire Insulation ColorPrimary Wire Insulation Color0 - Black 4 - Yellow 8 - Gray1 - Brown 5 - Green 9 - White2 - Red 6 - Blue3 - Orange 7 - Violet Conductor Size (AWG)
*Optional Shield MaterialH - High strength copper alloy, shield coating same as conductor coating (No designator defaults to coated “copper” shield, if any)Conductor Type1 - Tin-coated copper 2 - Silver-coated copper3 - Nickel-coated copper 4 - Silver-coated high strength copper alloy6 - Nickel-coated high strength copper alloyA - Silver-coated ultra high-strength copper alloyNumber of Conductors1 through 10 (designator for 10 conductor = 0)Class of Wire1 - 600 volt, lightweight2 - 600 volt, medium weight4 - 450V (55M 20-30 AWG only)7 - 1000 volt, heavy duty, airframe8 - 600 volt, normal weight, airframeConstructions0 - Primary wire; or unshielded & unjacketed cable1 - **Round braid shielded & jacketed cable 2 - ** Flat braid shielded& jacketed cable 3 - ** Round braid shielded cable, no jacket 4 - Jacketed cable, no shield5 - ** Spiral braid shielded & jacketed cable 6-9 - Special constructions
Product TypeA - General purposeAC - General purpose, 90% min. shield coverageAF - General purpose, low fluorideD - Defense Standard 61-12 Part 33LF - General purpose, ultra low fluorideLFC- General purpose, ultra low fluoride, 90% min. shield coverage M - 450 Volt
Basic Product Number
55 A 1 1 2 1 * - AWG - 2/6 - 9
(code per MIL-STD-681)
Part Numbering System55A and 55LF —General Purpose
**Except for p/ns with Shield Material designation “H”, shield coating same as conductor coating, except:- for Conductor Type 4, shield shall be tin-coated cooper- for Conductor Types 6 and A, flat braid only, shield shall be tin-coated copperThe UK manufactures and supply large volumes of 55Mx4x4 (450 volt) construction wires and cables for Aerospace and Multisport applications.
Part Numbering System is across reference only and notmeant for part creation.
Jacket Color (code per MIL-STD-681)Codes same as for Primary Wire Insulation ColorPrimary Wire Insulation Color0 - Black 4 - Yellow 8 - Gray1 - Brown 5 - Green 9 - White2 - Red 6 - Blue3 - Orange 7 - Violet Conductor Size (AWG)
*Optional Shield MaterialH - High strength copper alloy, shield coating same as conductor coating (No designator defaults to coated “copper” shield, if any)Conductor Type1 - Tin-coated copper 2 - Silver-coated copper3 - Nickel-coatedcopper 4 - Silver-coated high strength copper alloy6 - Nickel-coated high strength copper alloyA - Silver-coated ultra high-strength copper alloyNumber of Conductors1 thorugh 10 (designator for 10 conductor = 0)
Class of Wire1 - 600 volt, lightweight2 - 600 volt, medium weight3 - 600 volt, ultra lightweight4 - 300 volt (discontinued)7 - 1000 volt, heavy duty8 - 600 volt, normal weightConstructions0 - Primary wire; or unshielded & unjacketed cable1 - **Round braid shielded & jacketed cable 2 - ** Flat braid shielded & jacketed cable 3 - ** Round braid shielded cable, no jacket 4 - Jacketed cable, no shield5 - ** Spiral braid shielded & jacketed cable 6-9 - Special constructions
Product Type/ - Outer Space/F - Outer Space, low fluoride/LF - Outer Space, ultra low fluoride/P - Outer Space, shield coating same as conductor coating (valid with the following conductor types only: 4 for round braid; 4, 6 or A for flat braid)
Basic Product Number
55 / 1 3 2 1 * - AWG - 0/9 - 9
(code per MIL-STD-681)
9-16
SPEC 55 (Continued)
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Part Numbering System55/ — Outer Space
**For 55/: Except for p/ns with Shield Material designation “H”, shield coating same as conductor coating, except:- for Conductor Type 4, shield shall be tin-coated cooper; - for Conductor Types 6 and A, flat braid only, shield shallbe tin-coated copper. For 55/P, /LF: Shield coating same as conductor coating.For product released to ESCC 3901/012, 3901/020 and/or 3901/022, please refer to TE for product designation and construction.
Part Numbering System is across reference only and notmeant for part creation.
Jacket Color (code per MIL-STD-681)Codes same as for Primary Wire Insulation ColorPrimary Wire Insulation Color (code per MIL-STD-681)0 - Black 4 - Yellow 8 - Gray1 - Brown 5 - Green 9 - White2 - Red 6 - Blue3 - Orange 7 - Violet Conductor Size (AWG)
*Optional Shield MaterialH - High strength copper alloy, shield coating same as conductor coating (No designator defaults to coated “copper” shield, if any)Conductor Type1 - Tin-coated copper 2 - Silver-coated copper3 - Nickel-coated copper 4 - Silver-coated high strength copper alloy5 - Aluminum6 - Nickel-coated high strength copper alloyA - Silver-coated ultra high-strength copper alloyNumber of Conductors1 through 10 (designator for 10 conductor = 0)0 - 10 conductorsClass of Wire1 - 600 volt, lightweight, general purpose, single wall2 - 600 volt, medium weight, general purpose5 - 600 volt, lightweight, general purpose, dual wall7 - 1000 volt, heavy duty, airframe, general purpose8 - 600 volt, normal weight, airframe, general purposeConstructions0 - Primary wire; or unshielded & unjacketed cable1 - **Round braid screened & jacketed cable 2 - ** Flat braid screened & jacketed cable 3 - ** Round braid, screened cable, no jacket 4 - Jacketed cable, no shield5 - ** Spiral braid shielded & jacketed cable 6-9 - Special constructions
Product TypePC - Process ControlPCF- Process Control, low fluoridePCFL-Process Control, low fluoride (lite)PCL - Process Control (lite)PCT- Process Control (stripping thread under jacket, and shield, if any)PLF - Process Control, ultra low fluoridePLFL-Process Control, ultra low fluoride (lite)Basic Product Number
55 PC 1 1 2 4 * - AWG - 2/6 - 9
9Wire and Cable
9-17
SPEC 55 (Continued)
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Part Numbering System55PC and 55 PLF — Process Control
**Except for p/ns with Shield Material designation “H”, shield coating same as conductor coating, except:For 55PCL - for conductor type 6, flat braid only, shield shall be tin-coated copperFor 55PC and 55PCT - for conductor Type 4 and A, shield shall be tin-coated cooper
for Conductor Type 6, flat braid only, shield shall be tin-coated copper
Part Numbering System is across reference only and notmeant for part creation.
9-18
SPEC 55 (Continued)
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Typical Ordering Example 3 conductors, red, yellow, blue, 600 volt equipment wire with overall round braid, 20 AWG tinned conductor and white jacket: total part number is 55A1131-20-2/4/6-9.
Ordering Information A list of stock policy items can be identified by contacting TE.
Temperature Rating Conductor Material AWG Range Available Part Number MIL-SPEC No.600-V Lightweight Single-wall Hookup Wire, .152 [.006] Nominal Wall
6 1 55*21X6-AWG-Y 55*28X6-AWG-Y1Type of conductor or shield material: 2 X = no. of wire components1 = tin-coated copper Y = color code2 = silver-coated copper For complete part number, see Part Numbering System on page 9-15.3 = nickel-coated copper4 = silver-coated high-strength copper alloy6 = nickel-coated high-strength copper alloy* = A or PC
9-20
SPEC 55 (Continued)
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Basic Specification Number
Component Wire ID/Shield Coverage Code Shield Coverage 85% 90% Component Wire Identification - C Colored Stripes on White Wire (9/96/93/95/92/90/94/97/98/91... etc.) A D Solid Color Wires (9/6/3/5/2/0/4/7/8/1...etc.) B E Band Marks on Solid Colors (by AWG) F H Alternate Colored Stripes (92/96/94/95/9/90/91/93/97/98...etc) G J Alternate Solid Colors (2/6/4/5/9/0/1/3/7/8...etc.) K M Number Marking on Solid Colors (by AWG) L N Number Marking on White Wires P R Band Marks on Colored Stripes (by AWG) S T Band Marks on White Wires
Conductor Size (AWG)
Basic Wire Spec Code (SAE-AS-22759) and Slash SheetSB - 32 = 55A0111 SC - 33 = 55A0114 SD - 34 = 55A0811 for 2 AWG and larger, use 55A8039 SE - 35 = 55A0814 SM - 41 = 55A0813 for 2 AWG and larger, use 55A8595 SN - 42 = 55A0816 SP - 43 = 55A0812 for 2 AWG and larger, use 55A6089 SR - 44 = 55A0112 SS - 45 = 55A0113ST - 46 = 55A0116
Number of Component Wires1 through 9; 10 Components = 0
Jacket Material and Style Code00 - No jacket23 - Single jacket crosslinked, modified ETFE, white73 - Double jacket crosslinked, modified ETFE, white
M27500 X AWG XX X X XX
M27500-22SB3T23 = 55A1131-22-9/96/93-9
Tyco Electronics Part No.
Military Part No.
NEMA WC-27500 CablePart Numbering System
Example:
Part Numbering System is across reference only and notmeant for part creation.
FlexLine (SPEC 80)
9Wire and Cable
9-21
High Performance Wire and Cable
Applications
FlexLine wire (also knownas SPEC 80) is insulatedwith a flexible modified radiation cross-linked ETFEpolymer. It has a tempera-ture rating of -65°C to+200°C [-85°F to +395°F] continuous using silver copper conductor, andcombines the easy handling of our SPEC 55wire and cable with addi-tional flexibility. FlexLinewire is used in a broadrange of applications, fromHook-up wire to PowerCables.
Product Factsn Reduced weightn Flexibilityn Low outgassingn Function over a broadtemperature range
n Flammabilityn Arc track resistancen Resistance to atomic oxygenn Radiation resistancen High quality and reliabilityn Ease of fabrication (intoHarnesses due to flexibility)
n Agency approvalsn -65°C up to +200°C [-85°F up to +395°F]
n Small sizen 600V ratingn Optional high strand countfor increased flexibility
n Variety of insulation/jacketoptions
n Dual wall and single walloptions
n Easy to installn Mechanically toughn Compliance with FAR 25flammability requirements
n Resistance to harsh fluids &solvents per SAE-AS-22759
FlexLine wire constructions provide maximum flexibilitysimilar to the SAE-AS-22759products in Mechanical,Chemical and Thermalproperties.
Available in: Americas Europe Asia Pacific
n n n
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-22
FlexLine (SPEC 80) (Continued)
High Performance Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Jacket Color (code per MIL-STD-681)Codes same as for Primary Wire Insulation ColorPrimary Wire Insulation Color (code per MIL-STD-681)0 - Black 4 - Yellow 8 - Gray1 - Brown 5 - Green 9 - White2 - Red 6 - Blue 3 - Orange 7 - VioletConductor Size (AWG)Conductor Type1 - Tin-coated copper 4 - Silver-coated high strength 2 - Silver-coated copper copper alloy 3 - Nickel-coated copper 6 - Nickel-coated high strength copper alloyNumber of Conductors1 through 10 (designator for 10 conductor = 0) Class of Wire1 - 600 volt, lightweight8 - 600 volt, normal weight
Construction 0 - Primary wire or unshielded & unjacketed cable1 - *Round-braid shielded & jacketed cable2 - *Flat-braid shielded & jacketed cable3 - *Round-braid shielded cable, no jacket4 - Jacketed cable, no shield5 - *Spiral- braid shielded & jacketed cable6-9 Special constructionsProduct Type/ - Outer SpaceA - General PurposeAC- Same as A with 90% min. shield coverageB - DiscontinuedBasic Product Number81 - Normal Stranding82 - High Stranding
* Shield coating same as conductor coating except for the following: - for conductor type 4, shield shall be tin-coated copper - for conductor type 6, flat braid only, shield shall be tin-plated copper
82 A 1 1 2 1 - AWG - 0/9 - 9
FlexLine Insulation System
Single Wall Dual Wall
Single Wall 82 WireHigh strand count conductorsLight weightAWG sizes 28 to 00(6-mil nominal insulation thickness)
Part Numbering System81 & 82 — General Purpose, Outer Space
Part Numbering System is across reference only and notmeant for part creation.
Applications
Type 99M wire has a dualwall construction of radia-tion cross-linked modifiedpolyester. This combinesexcellent mechanical per-formance and chemicalresistance with a range ofenhanced fire hazard properties. Type 99M wireis designed to meet the stringent low fire hazardperformance now beingspecified by the UK NavalDefense Standard Authorityfor ship wiring and cabling.
During the 1980’s therewere major changes in thedemands of many wire andcable specifications toreduce the risks associatedwith all aspects of fire hazards. Specifications
such as Def Stan 61-12 Part 18, have been devel-oped over the last decadedemanding improved performance of wires and cables under fire conditions.
This has led to a tighteningof the requirements for flammability, smoke genera-tion, corrosive gas genera-tion and hazardous fume emission. Type 99M wireachieves these improve-ments in performance whilst retaining small size,light weight, flexibility, handleability, resistance tocarbon arc tracking andresistance to chemicals and fluids.
Physical Characteristics
Handleability
Type 99M wire has beendesigned to be compatiblewith modern wiring and harnessing techniques. It is a flexible wire with virtu-ally no springback onceset. It is easily stripped withtools such as conventional die-blade strippers.
Small Size
Type 99M equipment wirehas a nominal 0.2 mm insu-lation wall thickness whichis comparable to otherestablished thin wall wiressuch as SPEC 44 wire.
Light Weight
Type 99M wire is designedto have the same weightsas SPEC 44 wire.
Typical Properties (wire only)Test Method Typical valueTemperature rating BS 3G230 120°C [248°F]Voltage rating TE 600 V thin wallTensile strength/elongation of insulation — 30 MPa/250%Notch propagation (0.05 mm notch) BS 3G230 PassShrinkage 200°C [392°F] BS 3G230 <1%Low temperature bend BS 3G230 -55°C [-67°F]Voltage withstand BS 3G230 2.5 kVInsulation resistance (20°C [68°F]) BS 3G230 1000 M ohms km (min)Pliability rating Def Stan 61-12 (18) 82 - PliableFluid resistance Def Stan 61-12 (18)Fuels - aircraft PassOils - (IRM 903) PassSolvents Pass
Type 99M Wire and Cable -Nominal Sizes, Strandingsand Weights
Primary Wires/Shielded andJacketed Cables - 99M
99M011X (600 V)Primary Wire
99M1111Shielded & Jacketed
99M1121Shielded & Jacketed
Approvals
Type 99M (Continued)
9Wire and Cable
9-25
Low-Fire-Hazard Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Environmental Properties
Mechanical Performance
Type 99M wire has goodscrape abrasion and cutthrough performance com-plying with the requirementsof Def. Standard 61-12 Part 18.
Fluid Resistance
Type 99M wire demon-strates outstanding resist-ance to most acids, alkalis,hydrocarbon solvents, fuels,lubricants and water.
Electrical Arc Tracking
Type 99M wire is resistant toelectrical arc tracking.
Voltage Ratings
Standard available voltage ratings for Type99M wire is 600 V (0.2 mmwall thickness).
Fire Hazard Characteristics
Low Toxicity Index
Type 99M wire is designedto meet the low hazardousfume emission levelsrequired in modern specifi-cations. For example, thechange in the Toxicity Indexrequirement from 1.5 to 0.2between Issue 2 and Issue5 of Def Stan 61-12 (Part18), is met by Type 99Mwire.
Flammability
Type 99M wire has passedthe stringent flammabilitytest requirements of Def.Standard 61-12 (Part 18).
Smoke Generation
Type 99M wire has beendesigned to meet stringentsmoke tests such as thosespecified in Def Stan 61-12(Part 18).
Fire Hazard PropertiesTest Method Typical valueFlammability BS 3G230 PassToxicity index Def Stan 61-12 (18) 0.1 per meter of wireSmoke index Def Stan 61-12 (18) 8 per meter of wireAcid gas equivalent TDE 76/P/76 <1.5%
Corrosivity
Type 99M wire has a low corrosive gas emission, demonstrated by its low acid gas value,sufficient to pass therequirements of Def.Standard 61-12 Part 18.
9-26
Type 99M (Continued)
Low-Fire-Hazard Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Jacket Color(in accordance with MIL-STD-681, black preferred)
Primary Wire Insulation Color0=Black 1=Brown 2=Red 2L=Pink 3=Orange 4=Yellow 45=Yellow/Green 5=Green 6=Blue 7=Violet 8=Grey 9=WhiteAdditional number after base color indicates stripe
Conductor Size
Conductor Type1 - Tin-plated copper
Number of Conductors1, 2, 3, 4 etc.
Class of Wire1 - 600V equipment wire
Constructions0 - Primary wire & unscreened, unjacketed cables1 - Round braid screened & jacketed*9 - Special construction
Wire TypeM - Military wire
Basic Specification Number
99 X X X X X- Size- X/X- X
Part Numbering System
* The cable jackets are TE Zerohal and the preferred color is black.
Part Numbering System is across reference only and notmeant for part creation.
Zerohal 100A
9Wire and Cable
9-27
Low-Fire-Hazard Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Applications
TE’s latest generation LFH,thinwall wire has beendesigned for use primarilyin signal, control and lightpower circuits in subway,regional and high speedtrains. It is ideal for applica-tions where space andweight are at a premium;fire safety is important; relia-bility is imperative; ruggedproperties to withstandservice in an RMT environ-ment are required.
The construction is a dualwall combination of TE formulated polymer blendsdeveloped to meet thespecification requirementswhile maintaining the desir-able features of small size,lightweight, flexibility, non-wrinkling, ease of stripping,compatibility with standard
stripping equipment, lack ofrecoil and mechanicalrobustness.
Physical Characteristics
Handleability
Zerohal 100A wire has beendesigned for minimumrecoil during harnessingoperations, to be readilyhandleable by modernwiring and harnessing techniques and to be easily stripped with stan-dard equipment and tools.
Conductor - tin plated copper
Insulation - dual wall modified polymer blend
Product Factsn Halogen free, low smoken Highly flame retardantn Flexible, easy to installn Small size, lightweight (thinwall construction)
Available in: Americas Europe Asia Pacific
n n n
9-28
Zerohal 100A (Continued)
Low-Fire-Hazard Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Dynamic Cut Through ASTM D3032 20 lbs. minimum(90°, 0.01 inch radial edge blade, 0.2 inch per min, 20°C [68°F])
Static Cut-through AAR S 501 No contact with the conductorPenetration (90°, 0.01 inch radial edge blade, 10 min, 9N load, 125°C [257°F])
Thermal PropertiesTemperature Index ASTM D3032 10,000 hours minimum at 125°C [257°F]Accelerated ageing ASTM D3032 No cracks, flow or dielectric breakdown. (168hr at 170°C [338°F])Shrinkage IEC 811-1-3 0.5% maximum at each end. (6hr at 160°C [320°F)
Insulation Blocking MIL-W-22759E Cores must be easily separated without damage(24hr at 125°C [257°F], 6X mandrel.)
Electrical Properties>10000 MΩkft at 20°C [68°F]
IR Constant ASTM D3032 >100 MΩkft at 60°C [140°F]>10 MΩkft at 90°C [194°F]
Flammability - small scale IEC 332-1 Charring confined between 50mm and 540mm from lower edge of top support. (Single vertical wire, 60 s flame)
Flammability - large scale IEC 332-3 2.5m maximum burn length.(Five 3.5m long 37-wire bundles, vertical, 20.5 kW flame)Ds1.5 of 100 max., Ds4 of 150 max.,
Smoke - small scale ISO 5659-2 Dmax of 150 max., VOF4 of 300 max.(‘NBS’ smoke box with cone heater, 1.8m of wire50 kW/m2 heat flux with and without a pilot flame)90% minimum transmittance.
Toxicity IMO FTPC Toxicity index < 1 (Test conditions as in smoke - small scale)Halogen Content IEC 684-2 Less than 0.2% Cl + Br + I. Less than 0.1% F (Wet chemical analysis)Copper Mirror Corrosion ASTM D2671 5% maximum etched area. (0.4g sample, 200°C [392°F], 16hr.)
Acid Gas Detection IEC 754-2 pH greater than 4.3 10 µS/mm maximum(1g sample, tube furnace, T > 935°C [1715°F], gases dissolved in water)
Ordering Information
Finished WireConductorMaximum Diameter Maximum
Wire Stranding Diameter Resistance Weight Part No.Size No x AWG
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Fire Hazard PropertiesTest Method Typical Value
Flammability - small scale IEC 332-1 Charring confined between 50mm and 540mm from lower edge of top support. (Single vertical wire, 60 s flame)
Flammability - large scale IEC 332-3 2.5m maximum burn length.(Five 3.5m long 37-wire bundles, vertical, 20.5 kW flame)
Flammability IEEE 383 PassDs1.5 of 100 max., Ds4 of 150 max.,
Smoke - small scale ISO 5659-2 Dmax of 150 max., VOF4 of 300 max.(‘NBS’ smoke box with cone heater, 1.8m of wire50 kW/m2 heat flux with and without a pilot flame)Smoke density - Ds4 (Max.)
Toxicity IMO FTPC Toxicity index < 1 (Test conditions as in smoke - small scale)Halogen Content IEC 684-2 Less than 0.2% Cl + Br + I. Less than 0.1% F (Wet chemical analysis)Copper Mirror Corrosion ASTM D2671 5% maximum etched area. (0.4g sample, 200°C [392°F], 16hr.)
Acid Gas Detection IEC 754-2 pH greater than 4.3 10 µS/mm maximum(1g sample, tube furnace, T > 935°C [715°F], gases dissolved in water)
Environmental Properties
Fluid Resistance
Zerohal 100A wire demon-strates an outstanding balance of resistance to awide range of commonlyused solvents, fluids and lubricants.
Voltage Rating
Zerohal 100A wire is a 600volt rated wire.
Fire Hazard Characteristics
Zerohal 100A wire is a halo-gen free insulation systemand does not contain phos-phorus or sulphur. It meetsthe toxicity, smoke density,halogen content, corrosivityand flammability require-ments of major recognizedagencies.
Jacket Color 0 - Black2 - RedPrimary Wire Insulation Color0 - Black 4 - Yellow 8 - Gray1 - Brown 5 - Green 9 - White2 - Red 6 - Blue3 - Orange 7 - Violet
Conductor SizeConductor Type 1 - Tin-plated copperNumber of Conductors 1 to 9Class of Wire1 - 600 V equipment wireConstruction0 - Primary wire and unscreened, unjacketed cables1 - Roundbraid, screened and jacketed4 - Jacketed, no screenWire TypeA - AWG construction (US Specification)Basic Specification Number
100 A X X X X- Size- X/X - X Part Numbering System
Part Numbering System is across reference only and notmeant for part creation.
9-30
Zerohal 100G
Low-Fire-Hazard Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Applications
Zerohal 100G wire was originally developed tomeet the requirements ofGerman Specification VG95218-20, Type E primarywire.
The construction is a dualwall combination of TE formulated polymer blendsdeveloped to meet thespecification requirementswhile maintaining the desir-able features of small size, lightweight, flexibility, non-wrinkling, ease of stripping,compatibility with standardstripping equipment, lack ofrecoil and mechanicalrobustness.
System
n System 100
Physical Characteristics
Handleability
Zerohal 100G wire hasbeen designed for minimumrecoil during harnessingoperations, to be readilyhandleable by modernwiring and harnessing techniques and to be easily stripped with standard equipment andtools.
Conductor - tin plated copper
Insulation - dual wall modified polymer blend
Product Factsn Meets requirements of VG95218-20 Type E
n Halogen free, low smoken Highly flame retardantn Flexible, easy to installn Small size, lightweight (thinwall construction)
Available in: Americas Europe Asia Pacific
n n n
Zerohal 100G (Continued)
9Wire and Cable
9-31
Low-Fire-Hazard Wire and Cable
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
TE Specification WSD912 (Electrical cables and insulated wires for signals and power.- Part 20: Single core insulated wires.)
Test Method Typical ValueMax. operating temperature VG 95218-20, ASTM D 3032 125°C [257°F] (20,000 h)
Insulation shrinkage (150°C) DIN VDE 0472 Pt 628, < 0.5%IEC 811-1-3Low temperature bend VG 95218 - Pt 2 -55°C [-67 °F]
Pressure test at high temperature DIN VDE 0472 Pt 609, 125°C [257°F] < 30% indentationIEC 811-3-1Heat aging (150°C, 6 h) DIN VDE 0472 Pt 303, No cracking, no dielectric(140°C, 120 h) IEC 811-1-2 breakdownVoltage rating VG 95218-20 750/1300 V ACAbrasion resistance VG 95218 - Pt 2 PassInsulation blocking (125°C) VG 95218 - Pt 2 PassVoltage withstand DIN VDE 0472 pt 509 Pass(23°C, 2.5 kV rms)
Insulation resistance DIN VDE 0472 pt 502, > 500 M ohms. km (20°C [68°F])IEC 885-1 > 0.5 M ohms. km (90°C [194°F])
Elongation at break DIN VDE 0472 pt 602, > 200%IEC 811-1-1
*NATO code. For further details please consult the German Standard VG 95218-20, Type E.
Approvals
Typical Properties
Primary Wire Insulation Color0 - Black 3 - Orange 7 - Violet 1 - Brown 4 - Yellow 8 - Gray2 - Red 5 - Green 9 - White2L - Pink 6 - Blue
Conductor SizeConductor Type 1 - Tin-plated copperNumber of Conductors 1Class of Wire1 - 750 V equipment wireConstruction0 - Primary wireWire TypeG - Meeting the performance requirements of German Specification VG 95218-20, Type EBasic Specification Number
100 G X X X X- Size- X Part Numbering System
Part Numbering System is across reference only and notmeant for part creation.
Fire Hazard PropertiesTest Method Typical valueToxicity Def. Standard 02-713 3.5Smoke density IEC 1034 Pt 1 and 2 95% light transmittanceHalogen content DIN VDE 0472 pt 815 Non-detected
Corrosivity of combustion gases DIN VDE 0472 pt 813, 5.0 pH, <4 µS/mmIEC 754-2 conductivity
Zerohal 100G wire demon-strates an outstanding bal-ance of resistance to a widerange of commonly usedsolvents, fluids and lubri-cants.
Voltage Rating
Zerohal 100G wire is a750/1300 V AC rated wire.
Fire Hazard Characteristics
Zerohal 100G wire is a halo-gen free insulation systemand does not contain phos-phorus or sulphur. It meetsthe toxicity, smoke density,halogen content, corrosivityand flammability require-ments of VG 95218-20,Type E.
Flammability
Zerohal 100G wire meetsthe flammability/burningbehavior requirements ofVG 95218-20, Type E.
Ordering InformationNominal Nominal
Part Cross Conductor Equivalent Conductor Minimum Maximum Diameter MaximumDescription Sectional Stranding AWG Diameter Insulation Resistance (mm) Weight
Area No./Dia Size (mm) Thickness @ 20° C Lower Upper (kg/km)mm2 (mm) (mm) (ohsm/km) Spec Target Spec
9-32Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Applications
TE materials technologyand expertise in processingallows the use of thinwallinsulation systems. The useof Zerohal-EN cross-linkedcable jacket completes thisproduct offering.
C-Lite cable products canoffer significant size andweight reduction, whencompared to conventionalinsulation systems, while atthe same time meeting keycriteria such as low fire hazard performance andmechanical robustness.
Crosslinked Molecular Chain
TE Raychem was the firstcompany to commercializeradiation cross-linking ofinsulation, initially for aero-space applications.
To achieve crosslinking a polymer product is exposed to high-energyradiation. This is generallydone by exposure to betaradiation (high-energy electrons) using an electron beam.
Product Factsn 30% lighter than standardcommercial cable for weightsavings reductions
n Reduced diameter meansthat smaller bend radius canbe used during installation
n Reduced and easier cablepulling time
Crosslinked insulations in wire and cable products are lightweight,mechanically tough andthermally stable.
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite Low Fire Hazard Lightweight Cables
9-33Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9Wire and Cable
Field of applicationInstrumentation andcommunication controlGeneral power and lighting
Voltage class 0.6/1kV
Temperature class 90°C
Flame retarded IEC 60332-1,-3
Cable jacket Zerohal
The new C-Lite cable range is constructed from flame retarded halogen free primary wireand crosslinked sheath materials.
Offering size and weight savings over traditional cables. The new C-Lite cable range issuitable for use in general power, lighting, communication, control and instrumentationapplications.
Core Identification
Standard2 Core
Others
Additional cores numbered sequentially
Color Coded2G
3G
5G
1
2 3
4
56
7
Approvals
DNV, LR, GL, ABS, KR, CCS,RMRS, NK, BV
Pending
RINA
Multicore UnscreenedCables
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105-SU
9-34
Light Blue White
Brown Light Blue
Brown
Black
Brown
Light BlueGray
Yellow w/green stripe
Light BlueYellow w/green stripe
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Ordering Description OD Under Nom Wall Nom OD Tolerance Nom weightjacket (mm) (mm) (mm) (mm) (kg/km)
STANDARDCL105-2x0.5 - SU 2.9 0.9 4.7 0.3 33
CL105-3x0.5 - SU 3.1 0.9 4.9 0.3 39
CL105-4x0.5 - SU 3.5 0.9 5.3 0.3 48
CL105-5x0.5 - SU 3.9 1.0 5.9 0.4 59
CL105-7x0.5 - SU 4.3 1.0 6.3 0.4 75
CL105-12x0.5 - SU 5.9 1.0 7.9 0.5 117
CL105-19x0.5 - SU 7.1 1.1 9.3 0.6 176
CL105-27x0.5 - SU 8.7 1.1 10.9 0.7 239
CL105-2x0.75 - SU 3.3 0.9 5.1 0.3 40
CL105-3x0.75 - SU 3.6 0.9 5.4 0.4 48
CL105-4x0.75 - SU 4 1.0 6.0 0.4 62
CL105-5x0.75 - SU 4.4 1.0 6.4 0.4 75
CL105-7x0.75 - SU 4.9 1.0 6.9 0.4 95
CL105-12x0.75 - SU 6.8 1.1 9.0 0.6 155
CL105-19x0.75 - SU 8.1 1.1 10.3 0.7 226
CL105-27x0.75 - SU 10 1.2 12.4 0.8 316
CL105-2x1.0 - SU 3.6 0.9 5.4 0.4 45
CL105-3x1.0 - SU 3.9 1.0 5.9 0.4 58
CL105-4x1.0 - SU 4.3 1.0 6.3 0.4 72
CL105-5x1.0 - SU 4.8 1.0 6.8 0.4 87
CL105-7x1.0 - SU 5.4 1.0 7.4 0.5 110
CL105-12x1.0 - SU 7.4 1.1 9.6 0.6 180
CL105-19x1.0 - SU 8.9 1.2 11.3 0.7 271
CL105-27x1.0 - SU 10.9 1.2 13.3 0.9 372
CL105-2x1.5 - SU 4.3 1.0 6.3 0.4 64
CL105-3x1.5 - SU 4.6 1.0 6.6 0.4 82
CL105-4x1.5 - SU 5.1 1.0 7.1 0.5 97
CL105-5x1.5 - SU 5.7 1.0 7.7 0.5 119
CL105-7x1.5 - SU 6.3 1.1 8.5 0.6 158
CL105-12x1.5 - SU 8.8 1.2 11.2 0.7 259
CL105-14x1.5 - SU 9.3 1.2 11.7 0.8 295
CL105-19x1.5 - SU 10.5 1.2 12.9 0.8 385
CL105-24x1.5 - SU 12.6 1.3 15.2 1.0 488
CL105-27x1.5 - SU 12.9 1.3 15.5 1.0 540
CL105-37x1.5 - SU 14.7 1.4 17.5 1.1 725
CL105-2x2.5 - SU 5.2 1.0 7.2 0.5 91
CL105-3x2.5 - SU 5.6 1.0 7.6 0.5 118
CL105-4x2.5 - SU 6.3 1.1 8.5 0.6 153
CL105-5x2.5 - SU 7 1.1 9.2 0.6 181
CL105-7x2.5 - SU 7.8 1.1 10.0 0.7 235
CL105-12x2.5 - SU 10.7 1.2 13.1 0.9 391
CL105-19x2.5 - SU 12.9 1.3 15.5 1.0 597
CL105-27x2.5 - SU 15.8 1.4 18.6 1.2 838
CL105-37x2.5 - SU 18 1.5 21.0 1.4 1129
COLOR CODEDCL105-2Gx0.5 - SU 2.9 0.9 4.7 0.3 33
CL105-3Gx0.5 - SU 3.1 0.9 4.9 0.3 39
CL105-5Gx0.5 - SU 3.9 1.0 5.9 0.4 59
CL105-2Gx0.75 - SU 3.3 0.9 5.1 0.3 40
CL105-3Gx0.75 - SU 3.6 0.9 5.4 0.4 48
CL105-5Gx0.75 - SU 4.4 1.0 6.4 0.4 75
CL105-2Gx1.0 - SU 3.6 0.9 5.4 0.4 45
CL105-3Gx1.0 - SU 3.9 1.0 5.9 0.4 58
CL105-5Gx1.0 - SU 4.8 1.0 6.8 0.4 87
CL105-2Gx1.5 - SU 4.3 1.0 6.3 0.4 64
CL105-3Gx1.5 - SU 4.6 1.0 6.6 0.4 82
CL105-5Gx1.5 - SU 5.7 1.0 7.7 0.5 119
CL105-2Gx2.5 - SU 5.2 1.0 7.2 0.5 91
CL105-3Gx2.5 - SU 5.6 1.0 7.6 0.5 118
CL105-5Gx2.5 - SU 7.0 1.1 9.2 0.6 181
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105-SU (Continued)
9-35
Wire and Cable
9
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Field of applicationInstrumentation andcommunication controlGeneral power and lighting
Voltage class 0.6/1kV
Temperature class 90°C
Flame retarded IEC 60332-1,-3
Cable jacket Zerohal
Core Identification
Standard2 Core
Others
Additional cores numbered sequentially
Color Coded2G
3G
5G
1
2 3
4
56
7
Approvals
DNV, LR, GL, ABS, KR, CCS,RMRS, NK, BV
Pending
RINA
The new C-Lite cable range is constructed from flame retarded halogen free primary wireand crosslinked sheath materials.
Offering size and weight savings over traditional cables. The new C-Lite cable range issuitable for use in general power, lighting, communication, control and instrumentationapplications.
Multicore Overall ScreenedCables
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105-SO
9-36
Light Blue White
Brown Light Blue
Brown
Black
Brown
Light BlueGray
Yellow w/green stripe
Light BlueYellow w/green stripe
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Ordering Description OD Under Nom Wall Nom OD Tolerance Nom weightjacket (mm) (mm) (mm) (mm) (kg/km)
STANDARDCL105-2x0.5 - SO 3.5 0.9 5.3 0.3 48CL105-3x0.5 - SO 3.7 0.9 5.5 0.4 55CL105-4x0.5 - SO 4.1 1.0 6.1 0.4 68CL105-5x0.5 - SO 4.5 1.0 6.5 0.4 79CL105-7x0.5 - SO 4.9 1.0 6.9 0.4 96CL105-12x0.5- SO 6.5 1.1 8.7 0.6 149CL105-19x0.5 - SO 7.7 1.1 9.9 0.6 208CL105-27x0.5 - SO 9.3 1.2 11.7 0.8 284
CL105-2x1.0 - SO 4.2 1.0 6.2 0.4 66CL105-3x1.0 - SO 4.5 1.0 6.5 0.4 78CL105-4x1.0 - SO 4.9 1.0 6.9 0.4 93CL105-5x1.0 - SO 5.4 1.0 7.4 0.5 110CL105-7x1.0 - SO 6 1.0 8 0.5 135CL105-12x1.0 - SO 8 1.1 10.2 0.7 214CL105-19x1.0 - SO 9.5 1.2 11.9 0.8 311CL105-27x1.0 - SO 11.5 1.3 14.1 0.9 427
CL105-2x1.5 - SO 4.9 1.0 6.9 0.4 85CL105-3x1.5 - SO 5.2 1.0 7.2 0.5 104CL105-4x1.5 - SO 5.7 1.0 7.7 0.5 122CL105-5x1.5 - SO 6.3 1.1 8.5 0.6 150CL105-7x1.5 - SO 6.9 1.1 9.1 0.6 187CL105-12x1.5 - SO 9.4 1.2 11.8 0.8 299CL105-14x1.5 - SO 9.9 1.2 12.3 0.8 337CL105-19x1.5 - SO 11.1 1.2 13.5 0.9 432CL105-24x1.5 - SO 13.3 1.3 15.9 1.0 558CL105-27x1.5 - SO 13.6 1.3 16.2 1.1 611CL105-37x1.5 - SO 15.6 1.4 18.4 1.2 828
CL105-2x2.5 - SO 5.8 1.0 7.8 0.5 116CL105-3x2.5 - SO 6.2 1.0 8.2 0.5 145CL105-4x2.5 - SO 6.9 1.1 9.1 0.6 183CL105-5x2.5 - SO 7.6 1.1 9.8 0.6 214CL105-7x2.5 - SO 8.4 1.1 10.6 0.7 271CL105-12x2.5 - SO 11.3 1.3 13.9 0.9 446CL105-19x2.5 - SO 13.6 1.3 16.2 1.1 668CL105-27x2.5 - SO 16.7 1.5 19.7 1.3 958CL105-37x2.5 - SO 18.9 1.6 22.1 1.4 1264
COLOR CODEDCL105-2Gx0.5 - SO 3.5 0.9 5.3 0.3 48 CL105-3Gx0.5 - SO 3.7 0.9 5.5 0.4 55 CL105-5Gx0.5 - SO 4.5 1.0 6.5 0.4 79
CL105-2Gx1.0 - SO 4.2 1.0 6.2 0.4 66 CL105-3Gx1.0 - SO 4.5 1.0 6.5 0.4 78 CL105-5Gx1.0 - SO 5.4 1.0 7.4 0.5 110
CL105-2Gx1.5 - SO 4.9 1.0 6.9 0.4 85 CL105-3Gx1.5 - SO 5.2 1.0 7.2 0.5 104 CL105-5Gx1.5 - SO 6.3 1.1 8.5 0.6 150
CL105-2Gx2.5 - SO 5.8 1.0 7.8 0.5 116 CL105-3Gx2.5 - SO 6.2 1.0 8.2 0.5 145 CL105-5Gx2.5 - SO 7.6 1.1 9.8 0.6 214
Note: For installation guidelines refer to TE installation guidelines document WT1189
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105-SO (Continued)
9-37
Wire and Cable
9
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Field of applicationInstrumentation andcommunication controlGeneral power and lighting
Voltage class 0.6/1kV
Temperature class 90°C
Flame retarded IEC 60332-1,-3
Cable jacket Zerohal
The new C-Lite cable range is constructed from flame retarded halogen free primary wireand crosslinked sheath materials.
Offering size and weight savings over traditional cables. The new C-Lite cable range issuitable for use in general power, lighting, communication, control and instrumentationapplications.
Core Identification
Pairs
1
2
3
Additional pairs numbered sequentially
Triples
1
2
3
Additional triples numbered sequentially
1 2
3 4
5 6
1 2 3
4 5 6
7 8 9
Approvals
DNV, LR, GL, ABS, KR, CCS,RMRS, NK, BV
Pending
RINA
Multipair and MultitripleUnscreened Cables
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105-PF/C-Lite CL105-TF
9-38
Light Blue White
Red Light Blue White
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Ordering Description OD Under Nom Wall Nom OD Tolerance Nom weightjacket (mm) (mm) (mm) (mm) (kg/km)
Note: For installation guidelines refer to TE installation guidelines document WT1189
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105-PF/C-Lite CL105-TF (Continued)
9-39
Wire and Cable
9
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Field of applicationInstrumentation andcommunication controlGeneral power and lighting
Voltage class 0.6/1kV
Temperature class 90°C
Flame retarded IEC 60332-1,-3
Cable jacket Zerohal
The new C-Lite cable range is constructed from flame retarded halogen free primary wireand crosslinked sheath materials.
Offering size and weight savings over traditional cables. The new C-Lite cable range issuitable for use in general power, lighting, communication, control and instrumentationapplications.
Approvals
DNV, LR, GL, ABS, KR, CCS,RMRS, NK, BV
Pending
RINA
Core Identification
Pairs
1
2
3
Additional pairs numbered sequentially
Triples
1
2
3
Additional triples numbered sequentially
1 2
3 4
5 6
1 2 3
4 5 6
7 8 9
Multipair and MultitripleIndividually ScreenedCables
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105/PI/C-Lite CL105-TI
9-40
Light Blue White
Red Light Blue White
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Ordering Description OD Under Nom Wall Nom OD Tolerance Nom weightjacket (mm) (mm) (mm) (mm) (kg/km)
PAIRSCL105-1x2x0.5 - PI 3.2 0.9 5 0.3 41CL105-2x2x0.5 - PI 6.1 1.0 8.1 0.5 87CL105-3x2x0.5 - PI 6.3 1.1 8.5 0.6 103CL105-4x2x0.5 - PI 7 1.1 9.2 0.6 126CL105-7x2x0.5 - PI 8.7 1.1 10.9 0.7 185CL105-10x2x0.5 - PI 10.1 1.2 12.5 0.8 255CL105-14x2x0.5 - PI 11.9 1.3 14.5 0.9 347CL105-19x2x0.5 - PI 13.8 1.4 16.6 1.1 462CL105-24x2x0.5 - PI 15.5 1.4 18.3 1.2 566CL105-37x2x0.5 - PI 19.2 1.6 22.4 1.5 856
CL105-1x2x0.75 - PI 3.4 0.9 5.2 0.3 46CL105-2x2x0.75 - PI 6.9 1.1 9.1 0.6 112CL105-3x2x0.75 - PI 7.1 1.1 9.3 0.6 132CL105-4x2x0.75 - PI 7.9 1.1 10.1 0.7 164CL105-7x2x0.75 - PI 9.9 1.2 12.3 0.8 250CL105-10x2x0.75 - PI 11.4 1.3 14 0.9 344CL105-14x2x0.75 - PI 13.4 1.3 16 1.0 462CL105-19x2x0.75 - PI 15.7 1.4 18.5 1.2 616CL105-24x2x0.75 - PI 17.5 1.5 20.5 1.3 769CL105-37x2x0.75 - PI 21.8 1.7 25.2 1.6 1164
CL105-1x2x1.0 - PI 3.7 0.9 5.5 0.4 55CL105-2x2x1.0 - PI 7.5 1.1 9.7 0.6 133CL105-3x2x1.0 - PI 7.7 1.1 9.9 0.6 159CL105-4x2x1.0 - PI 8.6 1.1 10.8 0.7 198CL105-7x2x1.0 - PI 10.7 1.2 13.1 0.9 306CL105-10x2x1.0 - PI 12.4 1.3 15 1.0 423CL105-14x2x1.0 - PI 14.6 1.4 17.4 1.1 579CL105-19x2x1.0 - PI 17.1 1.5 20.1 1.3 773CL105-24x2x1.0 - PI 19.1 1.6 22.3 1.4 965CL105-37x2x1.0 - PI 23.7 1.7 27.1 1.8 1448
CL105-1x2x1.5 - PI 4.4 1.0 6.4 0.4 73CL105-2x2x1.5 - PI 8.8 1.2 11.2 0.7 179CL105-3x2x1.5 - PI 9.1 1.2 11.5 0.7 211CL105-4x2x1.5 - PI 10.1 1.2 12.5 0.8 265CL105-7x2x1.5 - PI 12.6 1.3 15.2 1.0 406CL105-10x2x1.5 - PI 14.6 1.4 17.4 1.1 562CL105-14x2x1.5 - PI 17.2 1.5 20.2 1.3 769CL105-19x2x1.5 - PI 20.1 1.6 23.3 1.5 1027CL105-24x2x1.5 - PI 22.5 1.7 25.9 1.7 1283CL105-37x2x1.5 - PI 27.9 1.9 31.7 2.1 1943
TRIPLESCL105-1x3.0.75 - TI 3.7 0.9 5.5 0.4 54 CL105-2x3x0.75 - TI 7.4 1.1 9.6 0.6 132CL105-4x3x0.75 - TI 8.9 1.2 11.3 0.7 209CL105-7x3x0.75 - TI 11.1 1.2 13.5 0.9 309CL105-10x3x0.75- TI 14.7 1.4 17.5 1.1 449CL105-15x3x0.75 - TI 17.3 1.5 20.3 1.3 664
CL105-1x3x1.5 - TI 4.7 1.0 6.7 0.4 88CL105-2x3x1.5 - TI 9.5 1.2 11.9 0.8 213CL105-4x3x1.5 - TI 11.4 1.3 14 0.9 337CL105-7x3x1.5 - TI 14.2 1.4 17 1.1 521
Note: For installation guidelines refer to TE installation guidelines document WT1189
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105/PI/C-Lite CL105-TI (Continued)
9-41
Wire and Cable
9
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Field of applicationInstrumentation andcommunication controlGeneral power and lighting
Voltage class 0.6/1kV
Temperature class 90°C
Flame retarded IEC 60332-1,-3
Cable jacket Zerohal
The new C-Lite cable range is constructed from flame retarded halogen free primary wireand crosslinked sheath materials.
Offering size and weight savings over traditional cables. The new C-Lite cable range issuitable for use in general power, lighting, communication, control and instrumentationapplications.
Core Identification
Pairs
1
2
3
Additional pairs numbered sequentially
Triples
1
2
3
Additional triples numbered sequentially
1 2
3 4
5 6
1 2 3
4 5 6
7 8 9
Approvals
DNV, LR, GL, ABS, KR, CCS,RMRS, NK, BV
Pending
RINA
Multipair and MultitripleOverall Screened Cables
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105/PO/C-Lite CL105-TO
9-42
Light Blue White
Red Light Blue White
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Ordering Description OD Under Nom Wall Nom OD Tolerance Nom weightjacket (mm) (mm) (mm) (mm) (kg/km)
PAIRSCL105-1x2x0.5 - PO 3.5 0.9 5.3 0.3 48CL105-2x2x0.5 - PO 4.1 1.0 6.1 0.4 68CL105-3x2x0.5 - PO 6.2 1.1 8.4 0.6 109CL105-4x2x0.5 - PO 6.9 1.1 9.1 0.6 130CL105-7x2x0.5 - PO 8.3 1.1 10.5 0.7 178CL105-10x2x0.5 - PO 9.6 1.2 12 0.8 236CL105-14x2x0.5 - PO 11.2 1.3 13.8 0.9 312CL105-19x2x0.5 - PO 13 1.3 15.6 1.0 412CL105-24x2x0.5 - PO 14.5 1.4 17.3 1.2 504CL105-37x2x0.5 - PO 18.1 1.5 21.1 1.4 754
CL105-1x2x0.75 - PO 3.9 1.0 5.9 0.4 60CL105-2x2x0.75 - PO 4.6 1.0 6.6 0.4 82CL105-3x2x0.75 - PO 7 1.1 9.2 0.6 134CL105-4x2x0.75 - PO 7.7 1.1 9.9 0.6 162CL105-7x2x0.75 - PO 9.4 1.2 11.8 0.8 232CL105-10x2x0.75 - PO 10.8 1.2 13.2 0.9 301CL105-14x2x0.75 - PO 12.8 1.3 15.4 1.0 416CL105-19x2x0.75 - PO 14.8 1.4 17.6 1.1 541CL105-24x2x0.75 - PO 16.7 1.5 19.7 1.3 688CL105-37x2x0.75 - PO 20.7 1.6 23.9 1.6 1029
CL105-1x2x1.0 - PO 4.2 1.0 6.2 0.4 66CL105-2x2x1.0 - PO 4.9 1.0 6.9 0.4 93CL105-3x2x1.0 - PO 7.6 1.1 9.8 0.6 154CL105-4x2x1.0 - PO 8.4 1.1 10.6 0.7 186CL105-7x2x1.0 - PO 10.3 1.2 12.7 0.8 269CL105-10x2x1.0 - PO 11.8 1.3 14.4 0.9 360CL105-14x2x1.0 - PO 13.9 1.4 16.7 1.1 496CL105-19x2x1.0 - PO 16.3 1.5 19.3 1.3 669CL105-24x2x1.0 - PO 18.2 1.5 21.2 1.4 809CL105-37x2x1.0 - PO 22.5 1.7 25.9 1.7 1226
CL105-1x2x1.5 - PO 4.9 1.0 6.9 0.4 85CL105-2x2x1.5 - PO 5.7 1.0 7.7 0.5 122CL105-3x2x1.5 - PO 8.9 1.2 11.3 0.7 206CL105-4x2x1.5 - PO 9.9 1.2 12.3 0.8 251CL105-7x2x1.5 - PO 12.1 1.3 14.7 1.0 367CL105-10x2x1.5 - PO 14 1.4 16.8 1.1 508CL105-14x2x1.5 - PO 16.6 1.5 19.6 1.3 703CL105-19x2x1.5 - PO 19.1 1.6 22.3 1.4 915CL105-24x2x1.5 - PO 21.6 1.7 25 1.6 1161CL105-37x2x1.5 - PO 26.5 1.9 30.3 2.0 1703
TRIPLESCL105-1x3x0.75 - TO 4.2 1.0 6.2 0.4 69CL105-2x3x0.75 - TO 7.7 1.1 9.9 0.6 152CL105-4x3x0.75 - TO 9.1 1.2 11.5 0.7 223CL105-7x3x0.75 - TO 11.2 1.2 13.6 0.9 318CL105-10x3x0.75 - TO 14.8 1.4 17.6 1.1 472CL105-15x3x0.75 - TO 17.4 1.5 20.4 1.3 697
CL105-1x3x1.5 - TO 5.2 1.0 7.2 0.5 104CL105-2x3x1.5 - TO 9.7 1.2 12.1 0.8 231CL105-4x3x1.5 - TO 11.5 1.3 14.1 0.9 342CL105-7x3x1.5 - TO 14.3 1.4 17.1 1.1 520
Note: For installation guidelines refer to TE installation guidelines document WT1189
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105/PO/C-Lite CL105-TO (Continued)
9-43
Wire and Cable
9
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-44
C-Lite CL105-PIO/C-Lite CL105-TIO
Signal and Control Cables forOffshore and Commercial Shipping
Field of applicationInstrumentation andcommunication controlGeneral power and lighting
Voltage class 0.6/1kV
Temperature class 90°C
Flame retarded IEC 60332-1,-3
Cable jacket Zerohal
The new C-Lite cable range is constructed from flame retarded halogen free primary wireand crosslinked sheath materials.
Offering size and weight savings over traditional cables. The new C-Lite cable range issuitable for use in general power, lighting, communication, control and instrumentationapplications.
Core Identification
Pairs
1
2
3
Additional pairs numbered sequentially
Triples
1
2
3
Additional triples numbered sequentially
1 2
3 4
5 6
1 2 3
4 5 6
7 8 9
Approvals
DNV, LR, GL, ABS, KR, CCS,RMRS, NK, BV
Pending
RINA
Multipair and MultitripleIndividually and OverallScreened Cables
Light Blue White
Red Light Blue White
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Ordering Description OD Under Nom Wall Nom OD Tolerance Nom weightjacket (mm) (mm) (mm) (mm) (kg/km)
PAIRSCL105-1x2x0.5 - PIO 3.7 0.9 5.5 0.4 56CL105-2x2x0.5 - PIO 6.7 1.1 8.9 0.6 117CL105-3x2x0.5 - PIO 6.9 1.1 9.1 0.6 132CL105-4x2x0.5 - PIO 7.6 1.1 9.8 0.6 155CL105-7x2x0.5 - PIO 9.3 1.2 11.7 0.8 230CL105-10x2x0.5 - PIO 10.7 1.2 13.1 0.9 300CL105-14x2x0.5 - PIO 12.6 1.3 15.2 1.0 413CL105-19x2x0.5 - PIO 14.5 1.4 17.3 1.1 538CL105-24x2x0.5 - PIO 16.4 1.5 19.4 1.3 684CL105-37x2x0.5 - PIO 20.3 1.6 23.5 1.5 1023
CL105-1x2x0.75 - PIO 4.1 1.0 6.1 0.4 68CL105-2x2x0.75 - PIO 7.5 1.1 9.7 0.6 144CL105-3x2x0.75 - PIO 7.7 1.1 9.9 0.6 165CL105-4x2x0.75 - PIO 8.5 1.1 10.7 0.7 200CL105-7x2x0.75 - PIO 10.5 1.2 12.9 0.8 294CL105-10x2x0.75 - PIO 12 1.3 14.6 0.9 395CL105-14x2x0.75 - PIO 14.1 1.4 16.9 1.1 544CL105-19x2x0.75 - PIO 16.6 1.5 19.6 1.3 735CL105-24x2x0.75 - PIO 18.4 1.5 21.4 1.4 891CL105-37x2x0.75 - PIO 22.9 1.7 26.3 1.7 1352
CL105-1x2x1.0 - PIO 4.4 1.0 6.4 0.4 78CL105-2x2x1.0 - PIO 8.1 1.1 10.3 0.7 167CL105-3x2x1.0 - PIO 8.3 1.1 10.5 0.7 194CL105-4x2x1.0 - PIO 9.2 1.2 11.6 0.8 243CL105-7x2x1.0 - PIO 11.3 1.3 13.9 0.9 360CL105-10x2x1.0 - PIO 13.1 1.3 15.7 1.0 492CL105-14x2x1.0 - PIO 15.5 1.4 18.3 1.2 682CL105-19x2x1.0 - PIO 18 1.5 21 1.4 891 CL105-24x2x1.0 - PIO 20.2 1.6 23.4 1.5 1131CL105-37x2x1.0 - PIO 24.8 1.8 28.4 1.8 1665
CL105-1x2x1.5 - PIO 5.1 1.0 7.1 0.5 96CL105-2x2x1.5 - PIO 9.4 1.2 11.8 0.8 219CL105-3x2x1.5 - PIO 9.7 1.2 12.1 0.8 252CL105-4x2x1.5 - PIO 10.7 1.2 13.1 0.9 310CL105-7x2x1.5 - PIO 13.3 1.3 15.9 1.0 476CL105-10x2x1.5 - PIO 15.5 1.4 18.3 1.2 664CL105-14x2x1.5 - PIO 18.1 1.5 21.1 1.4 889CL105-19x2x1.5 - PIO 21.2 1.6 24.4 1.6 1200CL105-24x2x1.5 - PIO 23.6 1.7 27 1.8 1476CL105-37x2x1.5 - PIO 29 2.0 33 2.1 2197
TRIPLESCL105-1x3x0.75 - TIO 4.4 1.0 6.4 0.4 62CL105-2x3x0.75 - TIO 8 1.1 10.2 0.7 166CL105-4x3x0.75 - TIO 9.5 1.2 11.9 0.8 249CL105-7x3x0.75 - TIO 11.7 1.3 14.3 0.9 365CL105-10x3x0.75 - TIO 15.6 1.4 18.4 1.2 552CL105-15x3x0.75 - TIO 18.2 1.5 21.2 1.4 784
CL105-1x3x1.5 - TIO 5.4 1.0 7.4 0.5 113CL105-2x3x1.5 - TIO 10.1 1.2 12.5 0.8 255CL105-4x3x1.5 - TIO 12 1.3 14.6 0.9 388CL105-7x3x1.5 - TIO 14.9 1.4 17.7 1.2 599
Note: For installation guidelines refer to TE installation guidelines document WT1189
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite CL105-PIO/C-Lite CL105-TIO (Continued)
9-45
Wire and Cable
9
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Field of applicationInstrumentation andcommunication controlGeneral power and lighting
Voltage class 0.6/1kV
Temperature class 90°C
Flame retarded IEC 60332-1,-3
Cable jacket Zerohal
The new C-Lite cable range is constructed from flame retarded halogen free primary wireand crosslinked sheath materials.
Offering size and weight savings over traditional cables. The new C-Lite cable range issuitable for use in general power, lighting, communication, control and instrumentationapplications.
Conductor Finished WireMaximum
Standing Max Resistance Nominal NominalNo’ Dia Diameter @ 20°C Diameter Weight
Part Number (CL105-) (mm) (mm) (ohm/km) (mm) (kg/km)
Color Code: The *in the part number shall be replaced by a standard color code designator in accordance with Mil-Std-681
White preferred other colors available on request e.g. CL105-0111-0.5-9 White Insulation
Performance Requirements: To be tested to and meet the requirements of the issue in effect of DNV Type Approval Programme No. 6-827.11-1 (excluding sizesless than 0.5mm2) Note: For installation guidelines refer to TE installation guidelines document WT1189.
Approvals
DNV, LR, GL, ABS, KR, CCS,RMRS, NK, BV
Pending
RINA
Primary Wire (Switchboard Cable)
C-Lite Approvals
Approval Body Approval System Certificate NumbersDet Norske Veritas (DNV) Type Approval E-7276, E-7277,E-7278,
Program No. 6-827.11.1 E-7279, E-7280, E-7281 Lloyds Register (LR) 2002 Type Approval System 99/0154(E1)Germanischer Lloyd (GL) Type Approval System 33 106-6 HH, 33 108-6 HHAmerican Bureau of Shipping (ABS) Type Approval Program 06-LB158945-PDAKorean Register (KR) Type Approval LDN20867-EL001Russian Register of Shipping (RMRS) Type Approval 07.04389.260, 07.04390.260,
China Classification Society (CCS) Type Approval LD07W00001Nippon Kaiji Kyokai (NK) Type Approval TA07631M; TA07630MPendingBureau Veritas (BV)Registro Italiano Navale (RINA) Additional Type Approvals on request
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite Cables
9-46Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Current Carrying Capacity
Current carrying capacity is defined as the continuous current which when passed througha wire will increase the temperature of the conductor from a specific ambient temperature to the maximum temperature rating of the insulation/sheath.
Temperature Rise v Current Guide
For Type CL105 in free air (single core)
Short Circuit Current
The short circuit current is based on the material the wire is made of, the cross sectionalarea of the wire and the maximum temperature rating of the insulation material. The shortcircuit current for a given wire size is provided in the table as constant current for a givenamount of time.
Signal and Control Cables forOffshore and Commercial Shipping
C-Lite Cables (Continued)
9-47
Wire and Cable
9
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Technical Information
9-48
C-Lite Cables (Continued)
Signal and Control Cables forOffshore and Commercial Shipping
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Examination or test Test basis Requirements Test onGeneral propertiesBraid coverage IEC 60092-350 90% minimum coverage density CableMetallic coating of copper IEC 60092-350 Conductor surface will be smooth and uniform. Conductorconductors by inspection Insulation will not adhere to the conductor.Physical propertiesTensile strength and ultimate IEC 60811-1-1 20MPa minimum, 150% minimum (insulation) Insulationelongation (speed 50±10 mm/min)Scrape abrasion resistance NF F 63-808 500 cycles minimum Core
(5N load, 0.45 mm diameter rod, 20°C,55 cycles/minute)
Dynamic cut through NF F 63-808 50N minimum Core(90° 0.13 mm radius blade, 20°C, 100g/s load)
Notch propagation NF F 63-808 No dielectric breakdown Core(0.05 mm notch, 6X mandrel, 1.5kV ac for 1 minute)
Mechanical/particular IEC 60092-350, 12.4 SHF1 or SHF2 Sheathcharacteristic of sheathing IEC 60092-359compounds Table II & IIIThermal propertiesLifetime BS 3G230 >20000h @ 120°C CoreAccelerated ageing IEC 60811-1-2 No cracks, no dielectric breakdown Core
(168h @ 150°C, 1.5kV ac for 5 minutes)Insulation blocking NF F 63-808 Cores must be easily separated (6h @ 150°C) CoreCold bend IEC 60811-1-4 No cracks, no dielectric breakdown(Where outer diameter <12.5 mm) (-30°C, 10X mandrel, 1.5kV ac for 5 mins for 1m core) Core
(-30°C, 10X mandrel, 3.5kV ac for 5 min. Sample of cable) Cable
Current overload BS 3G230 No cracks, no dielectric breakdown (30s @ 250°C, Core6X mandrel, wind as in lifetime test, 1.5kV ac for 5 minutes)
Electrical propertiesAC and DC voltage tests IEC 60092-350 No dielectric breakdown
(3.5kV ac/8.4kV dc for 5 minutes for 1m of core) Core(3.5kV ac/8.4kV dc for 5 minutes for each delivery length of cable) Cable
Insulation – continuity proof test IEC 60092-350 No dielectric breakdown CoreClause 10.3b At least 8kV impulse, 8kV dc or 3.5kV ac
Insulation resistance at 20°C IEC 60092-350 500MΩkM min. @ 20°C Core(5m length, quote actual IR)
Insulation resistance at 90°C IEC 60092-350 1.5MΩkM min @ 90°C Core(5m length, quote actual IR)
Increase in a.c. capacitance IEC 60092-350 C14-C1≤0.15 C1, C14-C7 ≤0.05C7 Coreafter immersion in water (14 days @ 50°C in tap water)Environmental propertiesOzone resistance IEC 60092-350 No crazing or cracking Core
IEC 60811-2-1 (250-300ppm, 25°C, 30h)Fluid immersion: 72h @ 70°C – BS 3G230 No cracking or dielectric breakdown 5% max, swell CoreIRM 902, IRM 903, Diesel (F-76), (6X mandrel, soak in water, 1.5kV ac for 5 minutes)3.5% salt waterFire hazard propertiesFlammability – small scale IEC 60332-1 Charring confined between 50mm and 540mm from Core
lower edge of top support (Single vertical wire)Flammability – large scale IEC 60332-3 Category A, designation F CableHalogen content IEC 60684-2 cl, 45 Less than 0.5% for each non metallic component CableToxicity index IMO FTPC It of less than 2, report Lc value Cable
Appendix 3Smoke emission – small scale ISO 5659-2 Ds4 150 max. and Dmax 150 max. VOF4 300 max. Core
Core IdentificationG - Color coded cores(No designator defaults to standard colors, light blue and white)
Number of ComponentsStandard construction - number of conductors Example: 2 = 2 conductors 3 = 3 conductors
Complex construction - number of component cables xnumber of wires in the component cable Example: 3x2 = 3 twisted pairs 7x3 = 7 twisted triples
Product Type90 - meets requirements of SHF1105 - meets requirements of SHF2
Basic Product Number
CL 105 - 3 G x 0.5 - S U
Part Numbering System
*also referred to as screened or unscreened
9-50
C-Lite F (Fire Resistant) Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Signal and Control Cables forOffshore and Commercial Shipping
Applications
TE is a major supplier inhigh performance cablesystems to the offshore andindustrial markets. Offshoreapplications includetelecommunications, instru-mentation and small powercables which representapproximately 80% of thetotal cable length on a platform.
Easy Design
C-Lite F cable consists of Raychem brand primaryC-Lite FR Wire with aZerohal-EN jacket and canbe used throughout an off-shore platform, simplifyingthe selection of cables fordesigners and electricalengineers.
Zerohal-EN Cables GenerateLess Smoke
Zerohal-EN is a halogen-free cable jacket material,developed by TE and com-bines the good mechanical, environmental and electricalfeatures of some conven-tional cables, with good firehazard performance.
Until recently the flameretardance of cable jacketswas achieved by the use of halogenated flame retardants that are effectivefire suppressants, but whichunfortunately producedense smoke and corrosive acid gases when burned.
Product Factsn Halogen freen Small sizen Lightweightn Tough flexible constructionn Resistant to hot diesel fuels,oils, grease, drilling fluids,and mechanical abuse
n Meets flame retardantrequirements of IEC 60332-3
n Controlled dimensionsn Mud resistant to NEK 606n Fire resistant to IEC 60331-31 (1000˚C)
These effects are highlyundesirable in a fire, causing corrosion damageto expensive and vitalequipment, hindering evac-uation and fire fighting andabove all, endangering life.
Benefits of Zerohal-EN cable
n Highly flame retardedn Low smoke generationn Low toxicity indexn Low acid gas generationn Operating temperature
-40°C up to +120°Cn Low water uptaken Compatible with
Raychem brand heat-shrink components -heat-shrink tubing,molded parts andadhesives.
The 10% visibility line on the graph
indicates the density of smoke
(measured in the NBS smoke
chamber) which would cause
human disorientation and confusion.
Smoke generation withtime
Available in: Americas Europe Asia Pacific
n
9Wire and Cable
9-51
C-Lite F (Fire Resistant) Cables (Continued)
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Signal and Control Cables forOffshore and Commercial Shipping
Cable trays
With more than 475 km of cabling on a typical large platform, thereare potential savings of up to 105 tons topside by using C-Litethroughout the platform. The total cabling system, together withsmaller cable glands, trays and transits can lead to overall weightsavings of approximately 165 tons and cost savings in excess of15%.
A typical saving in the
cable tray volume can
exceed 40%
Transits Over 40% savings
in area
The illustration above shows a TE light weight cable on the rightcompared with a traditional offshore cable having the same cross-sectional area of copper. Both cables have the same number ofconductors. A saving in size has been made on the insulationmaterial, but without sacrificing the mechanical or electrical characteristics of the cable.
Traditional Fire
Resistant Cable
C-Lite F
Cable
Designing Platforms
Platforms are becomingsmaller and more sophisti-cated with an ever increas-ing complexity of electronicsystems, sensors, commu-nications and safety equipment. More cables are therefore required to fitinto smaller spaces.
C-Lite F small size cablecan be a distinct advantageover conventional cables.
Space saving when refurbish-ing platforms
As technology advances,engineers are called uponto update and modify existing systems or fit completely new ones.
To provide all the necessaryinterconnections, hundredsof multicore cables have torun throughout the platform.These, along with cables for power, lighting andinstrumentation, create asevere space problem oncable trays, cable transitsthrough fire walls, marshalling boxes andgland plates.
Using C-Lite F cable instal-lation is easier because thecable is smaller, lighter,more flexible and has a reduced bend radius than conventional cables.
Lower total installed cost onnew platforms
Weight is one of the keyfactors to consider whendesigning new platforms.
Reduced size and weight in cables allow for smallerand lighter gauge rackingneeding less support. Also,smaller transits and cableglands reduce material andinstallation costs. C-Lite Fcable is easier to specify asit meets all the industry’sessential requirements inone cable.
Benefits of using TE C-Lite F cable
• Cable can be used throughout the platform
• Smaller tray work/more cables per tray
• Lighter supports
• Smaller cable glands/ gland plate optimization
• More cables through transit blocks
• Time saving on installation
• Less cable accessories
• Less inventory
• Lower total installed cost
• Wide size range:0.50-10.00mm2
9-52
FlexLite Commercial Wire
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Commercial Wire Family
Selection GuideApplication Temperature Rating (°C/°F) Features and Benefits Product Name
n Insulation that does not melt and flow at Intermittent-duty motors -45°C to 125°C high temperatures
FlexLite DWand heating elements -49°F to 257°F n Excellent chemical resistancen VW-1
Electronics, appliance, and -55°C to 135°C n Small size, light weightFlexLite TW
motor applications -67°F to 275°F n No plasticizers or corrosive outgassingn Excellent shop handling
General purpose 150°C n Excellent chemical resistanceFlexLite CW
commercial and industrial n Non-melting insulationn Insulation does not melt and flow at high temperature
Lighting, motor applications -55°C to 200°C n VW-1FlexLite HT
-67°F to 392°F n Excellent shop handlingn No cold-flow problemsn Very high temperature
Lighting, appliances, motors-65°C to 250°C n VW-1
FlexLite TX-85°F to 482°F n Superb chemical resistance
n Excellent shop handling
Primary Wire
Temperature Voltage AWGProduct UL Style Rating Rating Range Part Description
Note: Additional UL-recognized cable constructions are available. Please contact TE for details.*Available in both metric and imperial sizes.
UL Marking and Labeling
All FlexLite products are ULlabeled and reel marked.UL surface marking is additional. Please contact TE for further information.
FlexLite/UL Style Cross-Reference
Available in:Americas n
Europe n
Asia Pacific n
9Wire and Cable
9-53
FlexLite (Continued)
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Commercial Wire Family
FL XX X X X X X - Size - X/X - X
Basic Product Number
Product Type (UL Style - Temperature Rating)CW - UL Style 3751 - 150˚CDW - UL Style 3584 - 125˚CTW - UL Style 10208 - 135˚CHT - UL Style 3557 - 200˚CTX - UL Style 10297 - 250˚C
Conductor Stranding A - Solid B - 7 strand C - 19 strand D - 37 strand E - Rope Lay
Number of Conductors 1 through 10 (designator for 10 conductor = 0)
Conductor Size (AWG) or (Metric)
Jacket Color (code per MIL-STD-681) (codes same as for Primary Wire Insulation Color)
Construction 0 - Primary wire; or unshielded & unjacketed cable 1 - Round braid shielded & jacketed cable* 6 - Special constructions Class of Wire 1 - 150 volt 2 - 300 volt 3 - 600 volt
Conductor Type 1 - Tin-coated copper 2 - Silver-coated copper 3 - Nickel coated copper 9 - Bare copper
Primary Wire Insulation Color (code per MIL-STD-681) 0 - Black 3 - Orange 6 - Blue 9 - White 1 - Brown 4 - Yellow 7 - Violet 2 - Red 5 - Green 8 - Gray
*Shield coating same as conductor coating
Part Numbering System
Typical ordering example 19 strand, 20 AWG tin-coated copper, two component, shielded and jacketed cable, 600 volt, blue and whitecomponents, white jacket; part number FLDWC1321-20-6/9-9.
Ordering information For product requiring CUR (Canadian UL) or CSA marking part numbering descriptions above MIGHT NOT apply.Please contact TE for further information.
Part Numbering System is across reference only and notmeant for part creation.
9-54
FlexLite CW
Commercial Wire Family
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
General Purpose and MotorLead Wire
Applications
FlexLite CW (FLCW) isdesigned for general purpose Commercial andIndustrial applications. This dual wire combinesexcellent flexibility, shopfloor handling and stripping.
Product Factsn UL rated operatingtemperature to 150°C[302°F]
n Non melting cross-linkedinsulation material providescurrent overload andresistance to short termthermal excursions
n Insulation offers excellentperformance against mostfluids, including lubricatingoils, hydraulic fluids,cleaning fluids, acids andalkalis
n Varnish resistant for motorlead applications
n Excellent shop floorhandling enables ease oftermination and fullcompatibility with automaticcutting and strippingmachines
n 600 volt rating exceeds mostapplication needs
n Full range of sizes andcolors available
n Thin wall product improvespackaging possibilities
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Commercial Wire Family
Dual-Wall Primary Wire
Applications
FlexLite DW (FLDW) offers a high-performance non melting insulation suitable for a variety ofapplications, especiallythose with occasional high-temperature excursions,such as high-power battery-operated devices or intermittent-duty motors orheating elements.
0 = Black 3 = Orange 7 = Violet1 = Brown 4 = Yellow 8 = Gray2 = Red 5 = Green 9 = WhiteFor example:FLDWC0311-20-9 = AWG 20, white.
Construction DetailsFinished Wire
Nominal Wire Conductor Diameter Maximum Diameter NominalCSA Size Stranding
(min.) (max.)Resistance Lower Target Upper Weight in
Part No. (mm2) (No. x Dia.) at 20°C (68°F) Spec. Limit Value Spec. Limit kg/kmmm [inch] mm [inch] Ω/km [Ω /1000 ft] mm [inch] mm [inch] mm [inch] [lb/1000 ft]
* Replace asterisk with color code designator:0 = Black 3 = Orange 6 = Blue 9 = White1 = Brown 4 = Yellow 7 = Violet2 = Red 5 = Green 8 = GrayFor example: FLDWC0311-20-9 = AWG 20, white.
FLDWC0311-1.00-9 = Size 1.00 mm2, white.
For product requiring CUR (Canadian UL) or CSA marking in 16-10 AWG, stranded conductors only, the part numberingdescriptions above MIGHT NOT apply. Please contact TE for further information.
9-58
FlexLite TW
Commercial Wire Family
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Applications
FlexLite TW (FLTW) wireis commonly used in applications that demandsmaller, more rugged components, often in elevated temperatures.Designed to offer reducedsize while maintaining superior mechanical performance, FLTW in many cases is a lower-costsolution than expensive fluoropolymer wire.
Conductor Tin-coated copper
Insulation Modified polyester
Thin-Wall Hookup Wire and Cable
Product Factsn UL rated operatingtemperature to 135°C[275°F]
n Thin-wall product for sizeand weight savings
n Tough insulation materialn Excellent chemicalresistance
n Gauge sizes from 10-32AWG
n No plasticizers or corrosiveoutgassing, which can bedetrimental to sensitiveelectrical and electroniccomponents
* Replace asterisk with color code designator:0 = Black 3 = Orange 6 = Blue 9 = White1 = Brown 4 = Yellow 7 = Violet2 = Red 5 = Green 8 = GrayFor example: FLTWC0311-22-9 = AWG 22, white.
For product requiring CUR (Canadian UL) or CSA marking in 16-10 AWG, stranded conductors only, the part numberingdescriptions above DO NOT apply. Please contact TE for further information.
9-60
FlexLite HT
Commercial Wire Family
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
High-Temperature Hookup Wire
Applications
FlexLite HT (FLHT) wire is the product of choice for high-temperature applications. It offers shop-handling advantagesover silicone/ fiberglassconstructions (SF1/SF2)and is cost-competitive withother fluoropolymer wire.Applications include halogen lights, wirelesstools and small high-endappliances where spaceand temperature are issues.
Insulation Radiation-crosslinked, modified ETFE
Conductor Tin-coated copper
Product Factsn UL rated operatingtemperature to 200°C[392°F]
* Replace asterisk with color code designator:0 = Black 3 = Orange 6 = Blue 9 = White1 = Brown 4 = Yellow 7 = Violet2 = Red 5 = Green 8 = Gray For example: FLHTC0311-22-9 = AWG 22, white.
FLHTC0311-0.50-9 = Size 0.50mm2, white.
For product requiring CUR (Canadian UL) or CSA marking in 16-10 AWG, stranded conductors only, the part numberingdescriptions above DO NOT apply. Please contact TE for further information.
9-62
Thermocouple Extension Cable
Thermocouple Extension Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Applications
TE manufactures a broadrange of Raychem brandThermocouple extensioncables in four thermoele-ment combinations. Eachprovides accurate transmis-sion of electro-motive force(EMF) from a Thermocoupleelement lead wire of thesame conductor material toa thermometer, also knownas a pyrometer.
All four types of Thermocouple extensioncables use 19-strand con-ductors and are available intwisted pair, jacketedtwisted pair, and shieldedand jacketed twisted pair
Product Factsn 19-strand conductor for flexibility
n All 4 types available in different combinations
n Custom designs with different insulation systemsare available
n Lightweight, small size thermocouple extensioncables
configurations. A range ofcables is available from 16AWG to 24 AWG.
Wires and cables are insulated and jacketed with radiation-crosslinkedETFE, which has a continuous operating temperature of -65°C to+200°C [-85°F to +392°F].This material, which is fullyspecified in TE SPEC 55, has excellent physical properties and is highlyresistant to a wide range of chemicals.
Operating Temperature Range
-65°C to 200°C [-85°F to 392°F]
Available in: Americas Europe Asia Pacific
n n n
9Wire and Cable
9-63
Thermocouple Extension Cable (Continued)
Thermocouple Extension Cables
PropertiesInitial Calibration Tolerances for Thermocouple Extension Wires
Extension Thermoelement EMF (mv)*Cable Type Combination Temperature Range Limit of Range (min.–max.)EX Chromel-Constantan 0°C to 200°C [0°F to 392°F] ±1.7°C [35.1°F] 6.18–6.45JX Iron-Constantan 0°C to 200°C [0°F to 392°F] ±2.2°C [36.0°F] 5.15–5.39KX Chromel-Alumel 0°C to 200°C [0°F to 392°F] ±2.2°C [36.0°F] 4.00–4.19TX Copper-Constantan 0°C to 100°C [0°F to 212°F] ±1.0°C [32.0°F] 4.24–4.32
Note: The above is in accordance with ANSI-MC-96.1-1982.*EMF is measured in millivolts (mv) at 100°C [212°F] with reference junction at 0°C [0°F].
Twisted Pair Twisted, Shielded, 38 AWG
AWGTwisted, Jacketed Pair
Braid Strand, Jacketed Pair
Size Outside Weight Outside WeightOutside Weight
Diameter in kg/km Diameter in kg/kmDiameter in kg/km
**Dimensions for 19-strand-conductor thermocouple. Extension Types EX, JX, KX, and TX.
Product Dimensions**(Nominal)
Extension CableJacket Color codeType EX Chromel + Constantan - (if present) Wire Jacket
ANSI-MC-96.1 Violet Red Violet 7/2 7British Std.-BS 1843 Brown Blue Brown 1/6 1JIS-C-1602 Violet Red Violet 7/2 7IEC 584-3 Violet White Violet 7/9 7
Type JX Iron + Constantan - Jacket Wire JacketMIL-STD-687 Black Yellow White 0/4 9ANSI-MC-96.1 White Red Black 9/2 0British Std.-BS 1843 Yellow Blue Black 4/6 0JIS-C-1602 Red White Yellow 2/9 4IEC 584-3 Black White Black 0/9 0
Type KX Chromel + Alumel - Jacket Wire JacketMIL-STD-687 White Green White 9/5 9ANSI-MC-96.1 Yellow Red Yellow 4/2 4British Std.-BS 1843 Brown Blue Red 1/6 2JIS-C-1602 Red White Blue 2/9 6IEC 584-3 Green White Green 5/9 5
Type TX Copper + Constantan - Jacket Wire JacketMIL-STD-687 Red Yellow White 2/4 9ANSI-MC-96.1 Blue Red Blue 6/2 6British Std.-BS 1843 White Blue Blue 9/6 6JIS-C-1602 Red White Brown 2/9 1IEC 584-3 Brown White Brown 1/9 1
Color-Coding
Thermocouple extensioncables are available with thewires color-coded in accor-dance with five standards:MIL-STD-687, ANSI-MC-96.1, British Standard CodeBS 1843, Japanese JIS-C-1602 and IEC 584-3 colorcoding system (see bel0w)(International Standard)
Special Cables
Thermocouple extensioncables are also available insolid-conductor and seven-strand-conductor configura-tions. They come in avariety of thermoelementcombinations, gauges,
Extension Cableinsulations, and multiple-pair designs, and they areavailable for outer spaceapplications. Contact TE for details.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-64
Thermocouple Extension Cable (Continued)
Thermocouple Extension Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
The Thermocouple cableoptions outlined in the tableon the previous page canbe ordered from the tablebelow.
TE will assign a new partnumber on request forcables falling outside therange shown in the table.
Today’s performance needsfor military and commercialelectronic systems requireincreasingly sophisticatedequipment and greater useof composite structures andenclosures. As electronicsbecome more sensitive, the EMI protection level forelectrical equipment isincreasing. The Raychembrand of ElectroLossFilterLine wire and cableprovide a high degree ofEMI protection while func-tioning as conventionalelectrical wiring.
ElectroLoss FilterLine products include high-performance wire andcable, which when used as specified, suppress conducted and radiatedEMI above 100 MHz.
A reliable alternative to conventional discrete filtersand filter-pin connectors,ElectroLoss FilterLinecables are flexible, light-weight, and compatible withhigh-density connectors.
The ElectroLoss FilterLinewire and cable meets theperformance requirementsof SAE AS85485 originally amilitary specification devel-oped to provide EMI protec-tion for military electricalinterconnects.
The absorptive layer inElectroLoss FilterLine cableis constructed of a ferrite-loaded high-temperaturepolymer, which provideshigh-frequency EMI absorptive characteristics.Achieving maximum attenu-ation requires concentratingthe electromagnetic fields in the absorptive layer —
Radiation-crosslinked, modified ETFE
A
Absorptive layerConductor
Radiation-crosslinked PVDF
Absorptive layerConductor
Radiation-crosslinked, modified, conductive ETFE
Radiation-crosslinked, modified ETFE
A
Shield
Radiation-crosslinked PVDF
55FA0511 55FB1511
Product Factsn Suppresses EMI above 100MHz
n Light weight, small sizen SPEC 55 insulationn 600 voltn -65°C up to 200°C [-85°F to 392°F]
either with a metallic shieldon each wire or by an over-all metallic shield protectinga bundle of individual component wires.
Radiation-crosslinked, modified conductive EFTEjackets are used overshielded filter line cables to eliminate pathwaysbetween adjacent cableshields.
Application-driven alterna-tive ElectroLoss FilterLineconstructions built to thesame rigorous standardsdemanded of the militaryrequirements are also avail-able. These alternativesoffer significant weight savingsthrough the use of flatbraids, improved laser mark contrast, and a broaderchoice of conductors.
Available in:Americas n
Europe n
Asia Pacific n
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-66
ElectroLoss Filterline (Continued)
Controlled Electrical Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Performance
Effective against conductedEMI ElectroLoss FilterLinewire and cable systemsattenuate high-frequencyEMI and allow low frequencysignals to pass with mini-mum loss. When properlyinstalled and used, filter linewire and cables function as low-pass electrical filters, attenuating both
conducted and radiatedEMI above 100MHz. Theperformance of ElectroLossFilterLine product is bestdemonstrated by measuringthe attenuation (insertionloss) of a length of cableover a broad range of frequencies. Graph 1depicts typical insertionloss characteristics.
200
180
160
140
120
100
80
60
40
20
010 100 1000
1.2m
0.6m
0.3m
Attenuation
55FB1511-22 Frequency (MHz)
2 ft
1 ft
4 ft
Graph 1 - Typical insertion loss
Temperature rating -65°C up to 200°C [-85°F to 392°F]Voltage rating 600V r.m.s
9Wire and Cable
9-67
ElectroLoss Filterline (Continued)
Controlled Electrical Cables
Lightweight, RuggedizedFilterline Wire and Cable
Conductor Maximum Maximum MIL-SPEC TEAWG Stranding Outside Weight Part PartSize (Number x AWG) Diameter mm (in) Kg/Km (Ib/1000 ft) Number Number19 x 36 silver coated
24 high strength 1.19 [.047] 4.46 [3.0] M85485/10-24A 55FA0514-24-*copper alloy
22 19 x 34 tin coated 1.37 [.054] 5.95 [4.0] M85485/9-22A 55FA0511-22-*copper
20 19 x 32 tin coated 1.57 [.062] 8.63 [5.8] M85485/9-20A 55FA0511-20-*copper
18 19 x 30 tin coated 1.85 [.073] 12.95 [8.7] M85485/9-18A 55FA0511-18-*copper
16 19 x 29 tin coated 2.08 [.082] 16.67 [11.2] M85485/9-16A 55FA0511-16-*copper
14 19 x 27 tin coated 2.51 [.099] 23.96 [16.1] M85485/9-14A 55FA0511-14-*copper
12 37 x 28 tin coated 2.95 [.116] 35.71 [24.0] M85485/9-12A 55FA0511-12-*copper
10 37 x 26 tin coated 3.58 [.141] 55.06 [37.0] M85485/9-10A 55FA0511-10-*copper
Single Conductor WireSpecifications 150˚C Rated Wire
Conductor Maximum Maximum TEAWG Stranding Outside Weight PartSize (Number x AWG) Diameter mm (in) Kg/Km (Ib/1000 ft) Number19 x 36 silver coated
24 high strength 1.19 [.047] 4.46 [3.0] 55FAF7128-24-*copper alloy
* The color of component wire shall be light violet designated by 7L. The designated colors for components in finished cable shall be light violet for component 1 and light violet with stripe designators for remaining component wires as follows:Component wire 1 2 3 4 5Color designator 7L 7L6 7L3 7L5 7L2
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
The color of the component wire shall be light yellow designated by 4L. The designated colors for components shall be light yellow for component 1 and light yellow with stripe designators for remaining component wires as follows:
* The color of component wire shall be light violet designated by 7L. The designated colors for components in finished cable shall be light violet for component 1 and light violet with stripe designators for remaining component wires as follows:Component wire 1 2 3 4 5Color designator 7L 7L6 7L3 7L5 7L2
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
The color of the component wire shall be light yellow designated by 4L. The designated colors for components shall be light yellow for component 1 and light yellow with stripe designators for remaining component wires as follows:
ElectroLoss Filterline Wire and Cable Light WeightRuggedized Constructions —
150˚C
* The color of component wire shall be light violet designated by 7L. The designated colors for components in finished cable shall be light violet for component 1 and light violet with stripe designators for remaining component wires as follows:Component wire 1 2 3 4 5Color designator 7L 7L6 7L3 7L5 7L2
9Wire and Cable
9-71
ElectroLoss Filterline (Continued)
Controlled Electrical Cables
Lightweight, RuggedizedFilterline Wire and Cable(Continued)
Shield SizeAWG Number of AWG Maximum Maximum TESize Conductors Tin Coated Outside Weight Part Number
Fluid ResistanceHydrocarbonsFuels and lubricantsAlcohols
Fluids Cleaning fluidsGlycolsSynthetic fuels and lubricantsKetones
Electroloss Filterline Wire and Cable Light WeightRuggedized Constructions —
200˚C (Flat Braid)
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
The color of the component wire shall be light yellow designated by 4L. The designated colors for components shall be light yellow for component 1 and light yellow with stripe designators for remaining component wires as follows:Component Wire 1 2 3 4 5Color Designation 4L 4L6 4L3 4L5 4L2
9-72
ElectroLoss Filterline (Continued)
Controlled Electrical Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Part Numbering System
55F B 1 5 2 1- AWG- 7L/7L- 0
Basic Product Number
Construction0 - Component wire; or unshielded & unjacketed cable1 - Round braid shielded and jacketed cable*2 - Flat braid shielded & uacketed cable7 - Special constructions
Primary Wire Insulation Color(code per MIL-STD-681, except as noted) 0 - Black 5 - Green 9 - White1 - Brown 6 - Blue2 - Red 7 - Violet3 - Orange 7L - Light Violet4 - Yellow 8 - Gray
Jacket Color (code per MIL-STD-681) (codes same as for Primary Wire Insulation Color)
9Wire and Cable
9-73
Cheminax Coaxial Cables
Controlled Electrical Cables
Small, Lightweight CoaxialCables
Applications
Cheminax controlled electri-cal cables are used in theaircraft and aerospaceindustries. They have awide range of applicationsin missiles, avionics, radio-frequency and microwavesystems, computers, secu-rity and surveillance sys-tems, and communications.
Cheminax coaxial cableswere designed to solveinterconnect problems in
electronic systems, such ascomputers, military equip-ment, and other areas ofhigh-density packing, where cables are requiredto perform to more exacting specifications than standard radio-grade(RG) constructions.
TE’s advanced materialstechnology has allowed thedesign and development ofCheminax miniature coaxial
DCBA
A ConductorB DielectricC ShieldD Jacket
Product Factsn Light weight, small sizen Temperature range of -65°C to 200°C [-85°F to 392°F]
n Low capacitance and attenuation
n High velocity of propagationn High flexibility
cables that offer substantialsavings in size and weightwhile improving mechanicalperformance and reducingattenuation.
Cables can be designedthat are either smaller andlighter than standard RGcables or provide signifi-cantly lower attenuation andcapacitance with no signifi-cant increase in size.
Available in: Americas Europe Asia Pacific
n n n
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-74
Cheminax Coaxial Cables (Continued)
Controlled Electrical Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Jacket Color Identification Code0 - Black 4 - Yellow 8 - Gray1 - Brown 5 - Green 9 - White 2 - Red 6 - Blue 9X - Translucent White3 - Orange 7 - Violet X - Clear Conductor Type1 - Tin-coated copper 2 - Silver-coated copper3 - Nickel-coated copper4 - Silver-coated high strength copper alloy5 - Aluminum6 - Nickel-coated high strength copper alloy7 - Tin-coated copper-clad steel8 - Silver-coated copper-clad steel9 - Bare copper0 - OtherA - Silver-coated CS95 Dielectric Material1 - Rayfoam L (Polyethylene) 6 - Modified XL-ETFE (SPEC 55)2 - Rayfoam H (Foamed FEP) 7 - Flex XL-ETFE 3 - Rayolin F (Solid) 8 - Rayfoam M (Foamed MFA)4 - Modified FEP (Solid) 0 - Other
Note: To complement the mechanical and electrical features of Cheminax miniature coax cable, TE offers SolderSleeve, SolderTacts, and PinPak terminationdevices and RF connector devices. Controlled electrical cables and components are available for data bus systems.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Wire and Cable
9-77
Cheminax Twin Axial Cable
Controlled Electrical Cables
Small, Lightweight TwinAxial Cables
Applications
These small, lightweightcables are speciallydesigned for use in MIL-STD-1553 CANBUS,and other high speed databus applications. TE materialstechnology allows thedesign and construction ofcables that meet rigorouselectrical and environmentalperformance requirementswhile minimizing size andweight.
DCBA
A ConductorB DielectricC ShieldD Jacket
Product Factsn Light weight, small sizen Temperature range of -65°C to 200°C [-85°F to 392°F]
n Low capacitancen High data ratesn Excellent shop handling
Available in: Americas Europe Asia Pacific
n n n
Cheminax twin axial cablesprovide elegant solutions toan increasing range of databus and multiplex signaltransmission applications.
9
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-78
Cheminax Twin Axial Cables (Continued)
Controlled Electrical Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Product Dimensions*Typical A B C D Weight inProduct Impedance Capacitance Conductor Dielectric Shield Jacket kg/kmPart No. (ohms) pF/m(pF/ft) Diameter Diameter Diameter Diameter (lb/1000ft)
n Humidity resistant designsn Lightweightn Flexible
Available in: Americas Europe Asia Pacific
n n n
Applications
TE SeaLAN family ofwaterblocked and non-waterblocked Ethernetcables, as described inMIL-DTL-24643/59 through/61, are qualified to meetthe rigorous requirements of flammability, smoke emissions and halogen content. Waterblocked constructions meet severewaterblocking and humidityresistance requirements.
Cables are used in Ethernetapplications for:
n Military vessels MIL-DTL-24643/59, /60and /61
n Freighters
n Tankers
n Cruise Ships
9-80
SeaLAN Ethernet Cables (Continued)
Controlled Electrical Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
MIL Spec TEPart Description Type Description Cable DescriptionM24643/59-01UO LSC5FS-4 CEC-RWC-18982 24 AWG, solid bc,
Al/polyester and drain wire
M24643/59-02UO LSC5FSW-4 CEC-RWC-18983 Waterblocked, 24 AWG, solid bc, Al/polyester and
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
SHF-260 Highly Flexible Wire
Its ability to route in tightspaces may allow the userto go “up” in AWG sizesand eliminate the need tosplit power, where routingand bending previouslyprevented the user fromdoing so.
Applications
Typical uses include bothprimary and secondarypower distribution aero-space, defense and marineapplications where highamperage pass through isneeded
Thermal Shock Resistance:Accordance with ASS22759using an oven temperatureof 260˚C
Physical Properties
Weight and Dimensions:See TE SpecificationControl Drawings
Insulation Elongation:150% elongation minimum
Tensile Strength:2000 lbf/inch2 minimum
Minimum Bend Radius:290˚C for 500 hours arounda mandrel having a diameteras specified in the applicablespecification sheet
Wrap Test:Accordance with ASS22759using an oven temperatureof 290˚C
Fire Hazard Properties
Flammability – 60˚ Flame:Exceeds test requirements
Smoke:Smoke resistance test spec-ified in ASS22759 using anoven temperature of 290˚C
Electrical Properties
Voltage:1000 volts (rms)
Insulation Resistance:Minimum 50,000 Mohms/kft
Wire Printing
UV Laser Marking:Excellent mark contrast
Product Factsn Currently available in sizesfrom 24 to 1/0 AWG
n Highly flexible small bendradius allows for fitting intocomplex routing
n Extreme temperature resist-ance for a wide range ofapplications
n Extruded polymer notch andabrasion resistant —mechanically tough
n Chemical and fluid resist-ance when tested to SAE-AS-22759/41
n Vibration stability allows along life cycle in enginecompartments
TE Connectivity is pleasedto announce the introductionof its new SHF-260 highlyflexible wire. The need for acombination of hightemperature and highperformance in wireinsulation has become acritical factor in today’splatforms. This is especiallytrue in large diameter powerfeeder applications wheretemperature and durabilityare key.Its highly flexiblecharacteristic allows thecable to be bent and routedin extremely tight areas withno wrinkling or cracking ofthe insulation.This results inbeing able to run shorterdistances, reducing thestresson the contact, andreducing the mating anddemating forces normallyassociated with large shelldiameter circular connectors,such as MIL-C-5015 andMIL-C-83723 connectors.
9-82Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Raychem MIL-DTL-24643 ZEROHAL PROFIBUS Cables
Controlled Electrical Cables
Product Factsn MIL-DTL-24643/62 qualifiedn Waterblocked and non-waterblocked constructions
n Meets water tightnessrequirements when testedwith ASTM D1411 syntheticsea water solution
n Suitable for transmissionrates up to 12 megabits
n per second (MBits/S)n Compatible with commer-cially available Profibusconnectors
Available in: Americas Europe Asia Pacific
n n n
MIL-DTL-24643 has beenthe governing specificationfor low smoke, zero halogeninsulated and jacketedshipboard cables used by the United States Navyand other military marineapplications.
TE RAYCHEM brand ZEROHAL cables meetingthe PROFIBUS standard as described in MIL-DTL-24643/62, arequalified to meet the rigorous requirements toflame, smoke emissions,halogen content and severe water-blockingrequirements.
Applications
Cables are used in commu-nications, machinery control monitoring andinstrumentation for:
Military TEPart Number Type Part Number DescriptionM24643/62-01 LSPB2SD-1 5022M1809 22 AWG, bare copper,
non-water blocked, shield and jacket
M24643/62-02 LSPB2SDW-1 5022W1809 22 AWG, bare copper, water blocked, shield and jacket
M24643/62-03 LSPB2SDOS-1 5022M5809 22 AWG, bare copper, non-water blocked, two shields
and two jackets
M24643/62-04 LSPB2SDOSW-1 5022W0809 22 AWG, bare copper, water blocked, two shields
and two jackets
5022M5809 5022W0809 5022W18095022M1809
Cable Constructions
Product Offering
9-84Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
QUADLITE Quadraxial Cables
Controlled Electrical Cables
Product Factsn 100 Ohm and 150 Ohmcables
n Materials rated from -65˚Cto +200˚C [ -85˚F to +392˚F]
n Low outgassing materials(PTFE, FEP)
n Custom design capabilitiesn Proven technologies andmaterials
n Lightweightn Low smoke and low toxicityn Available in 150˚C and200˚C rated construction
TE Quadlite family of lightweight, fluoropolymercables are for use in highspeed, high bandwidthapplications such as100Base-T, Gigabit Ethernet,IEEE 1394 and Fiber Channelemployed in commercialavionics systems, aircraftdata networks, in-flightentertainment systems andmilitary communications.
The Quadlite cables aredesigned to meet the flam-mability requirements ofFAR Part 25 and the rigor-ous smoke and toxicityrequirements found in commercial aerospacestandards such as EN3475.
Quadlite cables are to beused with the Quadrax contacts and connectors.
Applications
Cables are used in communications, controland instrumentation for:
n In-Flight Entertainment
n Satellite TV
n Flight Subsystems
nMilitary Communications
Materials
Dielectrics— Foamed FEP
Jacket— FEP
Standards and Specifications
TE Specification 1200
ANSI/TIA-568-B.2
IEEE 1394
ARINC 664
Available in: Americas Europe Asia Pacific
n n n
9Wire and Cable
9-85Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-89Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
High Speed Copper Cable Assemblies
Controlled Electrical Cables
Product Factsn End-to-end best performancesystems solutions provider
n Quick design turnaroundusing in-house software
n Full electrical and environ-mental testing capability
n Certified test processes andequipment ensures optimalsignal integrity
n Qualified assembly expertsn Complete lot traceabilityn Reliability in harsh environ-ments
n ISO 9001; AS 9100 certified
TE supplies proven technol-ogy for high bandwidth datalinks to customers in theaerospace, ground systemsand marine industries.Military cable requirementsare designed, manufac-tured and tested to performreliably in harsh environments.
Proper cable assembly iscritical to realizing the fullpotential of the cable andconnector technologies.TE’s lightweight militarycables and connector solu-tions are designed toreduce size and removeweight from your applica-tion, leading to benefits thatinclude reduced fuel con-sumption and increasedpayload capacity.
Data assemblies can bedeveloped for the followinghigh speed protocols:
nMilitary Fiber Channel
n Ethernet (Fast Ethernet,GigE, 10GigE)
n 1394b Military Firewire
n USB 3.0
and many other serial communication architectures.
Applications
Unmanned aerial vehicles(UAV), Helicopters, Fighters,Transport, Trainers, Missiles,Satellites, and GroundVehicles
Applications include:
n Surveillance equipment,ground computing
n Communications
n Collision Avoidance,Navigation
n Cockpit Instrumentation
n Broadband Networks
n Command and Control
Electrical
Testing capabilities include:
n DWV/IR
n Characteristic Impedance
n Return Loss/VSWR
n Insertion Loss
n Crosstalk
n Attenuation
n Eye Diagrams
n etc.
Mechanical Tests Available:
n Vibration
n Mechanical Shock
n Mechanical Durability
Environmental Tests Available:
n Salt Spray
n Thermal Shock /Termperature Life
n Humidity / FluidImmersion
Available in:Americas n
Europe n
Asia Pacific n
9-90
Multiconductor (Multicore) Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
High Speed Copper Cables
in material sciences arecontinually developingunique polymer solutionsthat will reduce weight andsize while increasingrobustness of our products
Applications
Military Aerospace: SituationAwareness Systems (radar);Weapons Systems (missiles);Communications (radio andintercoms)
TE Connectivity offers alarge and growing range ofHigh Speed Copper Cablesfor commercial and militaryaerospace, as well as groundsystems and marine appli-cations. Increased usagesof high speed protocol suchas Ethernet, Firewire, FiberChannel and USB havebecome a necessity to beable to deliver informationfrom one point to the next.
TE’s high speed coppersolutions along with TE’smatched impedance con-tacts and connectors canprovide a total solution. TE’stotal solution can increasethe performance and thesignal integrity while main-taining robustness intoday’s Aerospace, Defenseand Marine applications.
TE’s expansive researchand development programs
Materials
Conductor: Tin, Silver,Nickel or Copper
Also available in HighStrength Alloys.
Electrical
Matched impedance con-nectors and cables
Electro-magnetic interfer-ences protection
150-Ohm FiberChannel
100-Ohm Gigabit Ethernet
Mechanical
Small size, reduced com-plexity and weight
Design Flexibility
CAD for quick response
High product performance
Optimum layout
Rapid quotations
Size and weight details
Product Factsn Reduced engineering timen Compatibility with numerous
TE contacts and TEtermination devices
n Integrated solutionn Cost savingsn Custom solutions availablen Complexity reduction for
straight forward installationn Increased bandwidthn EMI protectionn Lightning protectionn Ruggedized to survive in
harsh environmentsn Reduced size and weight
Dielectric Solutions
TE has designed a newprocess for extruding FoamedFEP and other variousjacket materials, allowing usthe advantage of providingrelatively uniform bubbles(void spaces) along theentire length of our cables.
This solution has a numberof benefits which includeincreased electrical per-formance and integrity whilemaintaining mechanicalrobustness.
Excellent uniformity (voidspaces); Excellent electricalperformance; More robustproduct
Wire and Cable
9
9-91
Multiconductor (Multicore) Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
High Speed Copper Cables (Continued)
HSC - part numbering system “high-speed conductor”
Example: C5E - 26 B 1 2 4 - 7 1 4 - 9X
Variation Code (3-digits): 3EA IEEE1394a C6X CAT6 DSP Display Port LVD LVD 3EB IEEE1394b C7E CAT7e DVI DVI TGX 1000B-T Quad C5E CAT5e C7X CAT7 FBC Fiber Channel THX 100B-T Quad C6A CAT6a CBS Canbus HDM HDMI UB2 USB 2.0 UB3 USB 3.0
Conductor AWG Size (Data Pair):
Conductor Stranding (Data Pair): A Solid B 7 Strand C 19 Strand
Conductor Material (Data Pair): reppoc eraB 9 reppoc detaoc-niT 1
Dielectric Material (Data Pair): 1 Rayfoam L 5 UXL-ETFE 0 Other 2 Rayfoam H 6 XL-ETFE L Low Fluoride XL-ETFE 3 Rayolin F 7 Flexible XL-ETFE 4 Modified FEP 8 Rayfoam FS
Number of Data Pairs:1 - 10 (designator for 10 conductor = 0)
Special Construction (P-Line = Power Line): - Standard C 26 AWG (P-Line) F 20 AWG (P-Line) W Waterblocked A 30 AWG (P-Line) D 24 AWG (P-Line) G 18 AWG (P-Line) X Special construction B 28 AWG (P-Line) E 22 AWG (P-Line) S Space rated
Shield Type: See page 2.
Shield Material (each, when more than one shield): 1 Tin-coated copper 4 Silver-coated high-strength copper alloy 2 Silver-coated copper U Unshielded 3 Nickel-coated copper
Jacket Material (each, when more than one jacket): 1 Thermorad K 8 Zerohal M Laser Markable FEP 3 Thermorad F & S 9 None N Thermorad NTFR 4 Modified FEP 0 Other R Raythane FR 5 UXL-ETFE C Raythane C T Thermorad O 6 Thermorad HT F FDR-25 W PET wrap 7 Thermorad FL L Low Fluoride XL-ETFE
Outer Jacket Color (code per MIL-STD-681, except as noted): (For translucent colors, an "X" is added to the end of the color. Example: 9X = Translucent White)
0 Black 3 Orange 6 Blue 9 White 1 Brown 4 Yellow 7 Violet X Clear 2 Red 5 Green 8 Gray
Rayfoam, Rayolin, Raythane, Thermorad, and Zerohal are trademarks.
9-92
Multiconductor (Multicore) Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
High Speed Copper Cables (Continued)
Description
Ethernet
Firewire
DVI
FiberChannel
USB-2.0
USB-3.0
Ethernet Category Cables
Markets: Commercial and MIL Aero, Marine, MilitaryGround Systems
Speeds: 10 Mbits/s to 10 Gbit/s
Common Names: Quadrax, Cat5e, Cat6, Cat 6a, Cat7
Primary Usage: Generalized Data Communications
FireWire/IEEE 1394
Markets: Aerospace Commercial and Military
Speeds: 100 Mbits/s to 3.2 Gbit/s
Primary Usage: High Data Rate Communication; BusIndependent
Fiber Channel
Markets: Aerospace
Speeds: 200 MB/s to 1.6 GB/s
Primary Usage: Storage Technologies and Long DistanceCommunications
Primary Usage: Universal Data Transfer- requires computingsystem to function
Digital Video Interface (DVI)
Markets: Marine and Ground Systems
Primary Usage: Video Displays, Uni-Directional Data Transfer
Wire and Cable
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Multiconductor (Multicore) Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
High Speed Copper Cables (Continued)
Compatible Products
The listing below is an “example” only of compatible products. For additional information, contact TE.
CeeLok FAS-T Connector Molded Shapes Band Straps SolderSleeve TerminationDevices
Gigabit EthernetConnectors
EN4165 Quadrax Contacts Twinax Contacts
Jacket MaterialsJacket Materials Temperature Range (˚C) Abrasion Resistance Flexibility Typical Industry Use
Thermorad K (Modified PVDF) -65 to +150 Very Good Fair Aerospace, Ground and MarineThermorad F & S -55 to +125 Good Good Ground SystemsModified FEP -65 to +200 Good Good AerospaceUXL-ETFE -65 to +150 Good Fair Aerospace and Ground SystemsThermorad HT (Modified ETFE) -65 to +200 Very Good Fair AerospaceThermorad FL -55 to +200 Very Good Good AerospaceZerohal -30 to +105 Good Good MarineFDR-25 -40 to +105 Fair Excellent Ground SystemsLow Fluoride XL-ETFE -65 to +200 Very Good Fair AerospaceLaser Markable FEP -65 to +200 Good Good AerospaceThermorad NTFR -55 to +110 Good Excellent Ground Systems and MarineRaythane FR -65 to +90 Excellent Excellent MarineThermorad O -55 to +125 Good Good Ground Systems and Marine
9-94
Multiconductor (Multicore) Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Custom-designed and standard Multiconductor (Multicore) Cables
Multiconductor (Multicore) Cables
Applications
TE is the leading manufac-turer of Raychem custom-designed, small-size,lightweight, high-performancemulti-conductor (multicore)cables. Applications arefound in the aerospace,commercial marine, naval,mass transportation, auto-motive, offshore, militaryground vehicle, groundsupport, high-performanceinstrumentation, industrial,and commercial markets.Raychem multiconductor(multicore) cables havebeen approved to manystandards demanding highperformance criteria in service use.
Multiconductor (Multicore)Cables Purpose Built andDesigned Using RaychemComponents and Technology
Multiconductor cables areused in widely varyingapplications and environ-ments. Careful considera-tion must be given to theselection of componentswith the right combination of physical, chemical, andelectrical properties for specific applications.
TE’s leadership in the technologies of polymerblending and subsequentradiation crosslinking hasled to the development of aparticularly broad range ofRaychem brand cables.High-performance compo-nent wires and miniaturecoaxial cables are com-bined with unique cable
Product Factsn Temperature capability:
-55°C to +260°C [-67°F to+500°F]
n Small size, lightweightn System compatibility with
other Raychem productsn Complete range of
componentsn Specially formulated jacket
materialsn Special shielding to address
EMI/EMC problemsn Custom designed and
purpose builtn Fast response—design,
pricing, and deliveryn Prototype length facilityn Raychem Dynalink for
extended flex-life andincreased flexibility
n Fire-resistance; circuitintegrity (IEC60331),enhanced 950˚C [1742˚F, 3 hours]
n Small size, lightweight, low fire-hazard for modernhigh-speed vessels
jacket materials to meet therequirements of demandingenvironments.
Established as the leadingmanufacturer of special purpose Raychem cables,TE has continued todevelop both its design and manufacturing expertise.
Development of a sophisti-cated CAD system hasallowed increasingly rapidresponse to any designrequest, followed by manufacturing to the highest quality standards.
Agency Industry Military TE
Underwriters’ Laboratories Lloyd’s Register of Shipping Def. Stan 61-12 Pt 25 WCD seriesCSA (Canadian Standards Assn.) Det Norske Veritas MIL-DTL-24640ISO9001:2000 MIL-DTL-24643MSV 34410-34413; 34435; 34436 VG 95218 Pts 27 and 28ANSI/ISO/ASQ Q9001-2000
Specifications/Approvals
Available in:
Americas n
Europe n
Asia Pacific n
Wire and Cable
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Multiconductor (Multicore) Cables
Multicore Cables
Components
n SPEC 44 wire and cable
n SPEC 55 wire and cable
n Type 99 wire and cable
n 100 wire and cable
Wraps and Braids
n Fabric and film tapes
n Aramid or steel strength members
n Full range of electrical screens (including SuperScreens)
Jacket Materials
n FDR 25 - Fluid resistant, flexible, hightemperature
n Thermorad/ - General purposeThermorad F
n Thermorad HTF - Very high temperature fluoroelastomer, fluid resistant
n Raythane C - Tough and flexible
n Raythane FR - Tough, flexible, flame-retardant
n Rayolin - Low moisture transmission
n NT/ - Low-temperature flexibilityThermorad NTFR
n Zerohal - LFH (Low Fire Hazard)
n ElectroLoss FilterLine cables
n Flexible power cables
n Optical fibers
n Controlled electrical cables
Design Flexibility
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-96
Multiconductor (Multicore) Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
How to Build a Multicore Cable
This guide is designed to help you identify the building blocks necessaryto create a custom multi-core cable design.
1. What is your application/end-use?
2. What temperature rating is required (in degrees C)?
3. How many components are needed?
4. What is each component used for (data, signal or power)?
5. What would be the size of each of the components (in AWG)?
6. Are there any electrical shielding (EMI) requirements? If so, please list specifics(ex: component shielding, cable shielding)?
7. Are there specific flexibility, mechanical, or fluid resistance requirements? If so, please list specifics and rank the order of importance.
8. Do you require special lengths?
9. Is there a customer specification involved? If so, please provide a copy.
10. Please list any timelines and annual usage estimates.
Wire and Cable
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Multiconductor (Multicore) Cables
Available in:
Americas n
Europe n
Asia Pacific n
Computer Aided Design
Applications
Every year, TE designs andbuilds several thousandcustom, high-performance,multiconductor cables thatmeet unique product needs.
Design staff can draw on an extensive range of high-performance cable compo-nents and jacket materials,while incorporating bothcolor-coding and alphanu-meric marking techniquesfor component identifica-tion. These options, com-bined with a full range ofEMI shields, lead to a hugevariety of construction possibilities.
TE developed computer-aided design tools to provide a fast response todesign requests. The soft-ware, used by factory engi-neers or product specialistsin the field, can generatecable design proposals with drawings and quotations inminutes. A design drawingdetails all the cable dataand can be used as theinput to harness or cablesplice (joint) design. Theresulting cable is tailored tocustomers’ exact needs inan efficient design that issuperior to the competitor’scable selected from a product catalog.
Quality Assurance
Raychem WCD and WSDcable specifications ensurethat performance and quality standards are main-tained to the highest level.TE manufacturing siteshave obtained the highestavailable quality systemapprovals, including ISO9000 and QS9000.Raychem cables are manufactured to meet therequirements of severalmajor specifications.
Custom Design Capability
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-98
Multiconductor (Multicore) Cables
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Custom Shipboard Cables
Product Factsn Waterblocked cables are
available using tapes andyarns vs. silicone, whichimproves size and flexibility
n Low smoke, zero halogenjackets compliant withcurrent MIL Specapplications
n Small order quantitiesavailable on most designs
n Lightweight state-of-the-artcable insulation technology
n TE design specialists workdirectly with customers
n RoHS products available
Applications
TE offers a full range of customized shipboardcables that can save userstime, money and weight bypackaging multiple cablesinto a single zero-halogenjacket per MIL-DTL-24640 specification.
Cables can be used for avariety of applicationsincluding control, lighting,signal and power.
Available in:
Americas n
Europe n
Asia Pacific n
Consolidation of individualcables for various applica-tions including weaponsand communicationssystems.
Data and power cables canbe combined in the samebundle to decrease weightand size on cable runs.
Wire and Cable
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RayBraid Tubular Braiding
Braids
Product Factsn Screening for military
harnessesn Easy removal from formern Minimum 90% optical
coveragen Ray 101 and Ray 103 super
flexible with high expansionratios
To ease the assembly ofhand built harnesses, TEmanufactures a range ofbraids for the electricalscreening of wire bundles.
RayBraid is supplied on atube former which facilitatesassembly and is morerobust than braid suppliedin flattened form.
TE also supplies connectors suitable for braid terminations.
Applications
When stored under typicalconditions of less than30Â˚C and less than 70%relative humidity, the shelflife of the wire is effectivelyunlimited. Where the prod-uct contains a standard tinplated or bare copper conductor or braid there willbe a progressive reductionin the solderability withincreasing storage time.Under the conditions mentioned above, excellentsolderability should beretained for about one yearfrom manufacturing date,but if this is an importantproperty, it should bechecked before use. Thesuitability of the tin plated orbare copper conductor foruse with crimped or weldedtermination techniques willnot be affected by storagetime.
Silver and nickel platedconductors are essentiallyunaltered by normal storage.
Types
Ray 90 (Tinned CopperBraid):
n Minimum 90% optical coverage available in 10different sizes from 3.0 to 30.0 mm supplieddiameter.
Ray 101 (Tinned CopperBraid):
n Minimum 93% maximum100% optical coveragepossess high usableexpansion ratio (minimum 2:1).
n Available in a wide rangeof sizes to cover 2.5 to38.0 mm diameters.
n Fully compatible withTinel-Lock adapters fortermination of the braid toassociated connectors.
Ray 103 (Nickel CopperBraid):
n Minimum 93% maximum100% optical coveragepossess high usableexpansion ratio (minimum2:1).
n Available in a wide rangeof sizes to cover 2.5 to38.0 mm diameters.
n Fully compatible withTinel-Lock adapters fortermination of the braid toassociated connectors.
Operating Temperature Range
Ray 90: up to 150˚C [302˚F]
Ray 101: up to 150˚C [302˚F]
Ray 103: above 150˚C [302˚F]
Tubular Braiding for theElectrical Screening ofWire Bundles
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-100Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
RayBraid Tubular Braiding (Continued)
Braids
Characteristics
Weight
Tinned Copper WirePart Number Diameter No. of No. of Individual Strand Minimum Cable Bundle Tolerance
of former Carriers Ends per Size (AWG/mm) Coverage Maximum Minimum(mm) Carrier (%) (mm) (mm)
ResistanceThe following current ratings are tobe used as general guidelines.Ratings based on an ambient temperature of 20˚C and a temperature rise above ambient of 40˚C.
Ray -90 Ray 101 Ray 103Part Number CSA mm2 Resistance @ Current CSA mm2 Resistance @ Current Resistance @
20˚C in ohms/km (amps) 20˚C in ohms/km (amps) 20˚C in ohms/km-3.0 1.0 28.0 17 1.3 17.0 18 17.3
Specifications and Approvals (Components and Jacket Materials)
Specifications
UK DesignationFDR Zerohal Fluoro- Thermorad Rayolin Raythane C AFR NT 44 55 100 99 Hytrel25 elastomer Wire Wire Wire Wire
US DesignationFDR
ZerohalThermorad
Thermorad F Raythane FRThermorad 44 55 100
25 HTF NTFR Wire Wire Wire
Def Stan 61-12 Part 31 XDef Stan 61-12 Part 25 X X XDef Stan 61-12 Part 18 type 1 (issue in effect ) X XDef Stan 61-12 Part 26 X34435, 34436 X XVG 95218 Part 20, 21, 22 and 23 X X XVG 95218 Part 24, 25 and 26 X VG 95218 Part 27 and 28 X X X XVG 95218 Part 1000 XVG 95218 Part 1001 and 1002 XMIL-DTL-24640 (PMS 400/MIl-C-915) X XSAE-AS-81044/NEMA WC27500 XSAE-AS-22759/NEMA WC27500 XA014000 X XO2-517 X X X
MIL-DTL-24643 X
Approvals
Lloyds Register of Shipping X X X X XBureau Veritas X X X X X X X X X UL X X (FR) X X XCSA X X BWB X X X XVDE X X X XGermanischer Lloyd X XAmerican Bureau of Shipping X X
* Please check with your TE representative to ensure the product required has the correct approval.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-102Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Cable Jacket Materials
Properties and Specifications (Continued)
Major Cable SpecificationsCountry Cable Specification Specification Description Approved Jacket
Royal Navy specification covering limited fire hazardUK Def Stan 61-12 Part 25 thin-wall insulated electric cables using ZerohalDef-Stan 61-12 Part 18 approved wire.
Signal, control and light power circuits.Military ground systems specification for signal, control
Germany VG 95218 (parts 27 and 28) and power cables. Wire to VG 95218 FDR-25Parts 20-23 and 1000. Navy specification covering limited fire hazard thin-wall
USA MIL-C-24640 (PMS 400/MIL-C-915) insulated electric cables for signal, control and light Zerohalpower circuits. Wire to SAE-AS81044.
USA MIL-DTL-24643 Navy specification covering low smoke, watertight, Zerohaland non-watertight electric cables for signal, control, and light power circuits for shipboard applications.
Summary of Typical Cable Jacket PropertiesProperty Chemical Resistance
UK Designation US Designation Temperature AbrasionFlexibility
FDR25 FDR25 -40 to 105 Fair Very Good 20 500 Self-ext;ing Good Good Very GoodZerohal Zerohal UK & US -30 to 105 Good Good 10 200 Self-ext;ing Good Good GoodFluoroelastomer Thermorad HTF -20 to 200 Good Good 12 400 Nonburning Excellent Excellent ExcellentThermorad Thermorad F -55 to 125 Good Good 22 400 Self-ext;ing Good Good GoodRaythane C — -25 to 80 Excellent Excellent 40 500 Self-ext;ing Fair Fair Excellent— Raythane FR -65 to 90 Excellent Excellent 28 500 Self-ext;ing Fair Fair ExcellentNT Thermorad NTFR -55 to 110 Very Good Excellent 17 300 Self-ext;ing Good Good GoodRayolin — -55 to 95 Very Good Fair 19 250 Self-ext;ing Good Good GoodAFR — -40 to 105 Excellent Good 10 150 Self-ext;ing Good Good Good— Thermorad O -55 to 125 Good Good 15 400 Self-ext;ing Good Good Good— Thermorad 770 -55 to 175 Very Good Good 35 500 Nonburning Excellent Excellent Excellent— Thermorad 780 -55 to 200 Very Good Good 24 350 Nonburning Excellent Excellent Excellent— Thermorad 790 -55 to 250 Very Good Good 30 350 Nonburning Excellent Excellent ExcellentModified PVDF Thermorad K -65 to 150 Very Good Fair 20 400 Nonburning Excellent Excellent ExcellentModified ETFE Thermorad HT -65 to 200 Very Good Fair 34 100 Self-ext;ing Excellent Excellent ExcellentModified Flexible ETFE Thermorad FL -55 to 200 Very Good Excellent 20 100 Self-ext;ing Excellent Excellent Excellent
— Thermorad HTOS -65 to 200 Very Good Very Good 34 100 Self-ext;ing Excellent Excellent Excellent— Thermorad HTLF -65 to 200 Very Good Very Good 34 100 Self-ext;ing Excellent Excellent Excellent— Thermorad HTASLF -65 to 200 Very Good Very Good 34 100 Self-ext;ing Excellent Excellent Excellent— Thermorad VPB -65 to 200 Very Good Very Good 23 500 Self-ext;ing Excellent Excellent Excellent
*Operating temperatures for cables are application dependent. Figures shown are for guidance only. In many cases the limits shown may be extended at bothends of the temperature range. Consult TE for guidance.
Wire and Cable
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Cable Jacket Materials
FDR25
Applications
FDR 25 cable jacket wasoriginally developed for theLeopard II main battle tankto provide an exceptionalrange of properties. Used incompartments exposed tohot diesel fuels and vibra-tion, FDR 25 resists a widerange of aggressive fluidsand offers excellent lowtemperature flexibility.These properties have alsoled to a widespread use ofFDR 25 on other militaryvehicles and in many appli-cations such as test andcommunications equip-ment. FDR 25 is fully com-patible with the RaychemSystem 25 high perform-ance harnessing system.
FDR 25
Flexible, Diesel ResistantWire and Cable JacketMaterial
Product Factsn Highly flame retardantn Compatible with Raychem
System 25 tubing, moldedparts and adhesives
n Qualified to VG standards
Operating Temperature Range
-40°C to 150°C [-40°F to 302°F]
Available in:
Americas n
Europe n
Asia Pacific n
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-104Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Cable Jacket Materials
FDR25 (Continued)
Typical Characteristics when Tested in Accordance with TE Specification WCD 2002 (UK) and WCD 3304 (US)Tensile strength (MPa) 20Elongation (%) 500
Mechanical Tear strength (N/mm) 5Abrasion resistance (1.6 kg load) 40 scrapes min.Cold bend -40°C [-40°F]Endurance IEC 60216-1 2500 h 150°C [302°F]
Thermal aging Heat aging 120h, 175°C [347°F] TS 8 MPa (min). Eb 150% (min)Heat shock 4 h at 225°C [437°F] No cracks, drips or flowing,
6 mm total shrinkage in 300 mm
24 h immersion % Retention of propertiesTensile strength Elongation
Electrical Insulation resistance 20°C [68°F] M ohm.km min. 245° flammability 30 s (max) afterburn
Other 100 mm (max) burn lengthVertical flammability Self extinguishingAcid gas 4% HCl equivalent (max.)
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Cable Jacket Materials
Zerohal
Applications
Cables rarely initiate fires,but they could be involvedin them and can signifi-cantly increase the damagecaused should they propa-gate the fire. Until recentlythe flame retarding ofcables was achieved by the use of halogenatedflame retardants which areeffective fire suppressants,but which unfortunately produce dense smoke andcorrosive acid gases whenburned. These effects arehighly undesirable in a fire,hindering evacuation andfire fighting, endangeringlife and causing corrosiondamage to expensive and vital equipment.
Raychem Zerohal is a halogen-free cable jacketmaterial developed by TE and approved to themost exacting requirementsfor low fire hazard cables inmany countries and, assuch, is the most widelyaccepted material for theseapplications in the marine,process and mass transportindustries. Combined withSPEC 44 wire or Type 99and 100 wire, this jacketmaterial provides smallsize, light weight cables(approximately 40% weightsaving over conventional materials).
Zerohal
Low Fire HazardPerformance Wire andCable Jacket Material
Product Factsn Halogen freen Low smoke generationn Highly flame retardantn Low toxicity indexn Low corrosive gas emissionn Temperature rating -30°C to
+105°C [-22°F to +221°F]
Zerohal combines the goodmechanical and electricalfeatures of some conven-tional cables with goodflame retardancy, lowsmoke generation, low evolution of hazardous andcorrosive gases, and goodresistance to diesel fuel,lubricating oils and water.
Zerohal jacket material isfully compatible with the low fire hazard harnessingsystem - System 100.
System
n System 100
Available in:
Americas n
Europe n
Asia Pacific n
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-106Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Cable Jacket Materials
Zerohal (Continued)
Typical Characteristics when Tested in Accordance with TE Specification WCD 2015 and WC 2001 (Zerohal with Fungicide)
Tensile strength (MPa) 9Elongation (%) 200
Mechanical Tear strength (N/mm) 5Abrasion resistance (1.6 kg load ) 30 scrapes min.Cold bend -30°C [-22°F]Heat aging 120 h 130°C [266°F] 60% min retention of TS and Eb
Thermal aging Heat shock 4 h at 225°C [437°F] No cracks, drips or flowing,6 mm total shrinkage in 300 mm
Retention of propertiesTensile strength Elongation
Other Limiting oxygen index 32%Temperature index 275°C [527°F]Toxicity index 2.5 per 100 gSmoke index 18Halogen content None detected
Low Fire Hazard Performance
Flammability
Current thinking on fire hazard defines the term‘Fire Risk’. This descriptionrecognizes that the risk in afire situation is influencedstrongly from several factorsincluding, ignitability, heatrelease, smoke evolutionand toxic gas emissiontogether with flammability.
There are several test procedures available usedto assess flammability ofwires and cables. Still inwidespread use is LimitingOxygen Index (LOI), but it isnow generally recognizedthat because the test isconducted on a singlespecimen (of cable jacketor wire) in laboratory condi-tions, the results are, atbest, only weakly correlatedto actual fire situations.Critical Temperature Index(CTI), is a related test andassesses performance atelevated temperature butnevertheless it is still con-ducted on a single speci-men. The most common
flammability tests for a sin-gle wire specimen is the 60˚flame test as defined byAS81044 and FAR Part25.More recent evidenceand thinking places signifi-cantly greater importanceon large scale flammabilitytests, such as IEC IEEE 383or UL1685, in which thesample consists of a tray ofwires. These tests predictmore accurately the likelybehavior of cables in actualfire scenarios. RaychemZerohal cable jackets givevery good results in smallscale laboratory basedtests (e.g. LOI, CTI) andZerohal cables performvery well in large scale tests (e.g. IEEE 383 orUL1685). Overall Zerohaljacketed cables have beenshown to exhibit excellent flammability characteristics.
Corrosivity
Under fire conditions, poly-mers containing halogens,sulphur and phosphorousall form corrosive acidgases or liquids. Theseacids can then attack itemssuch as printed circuit
boards, connectors, controlrelays and metal structures,including steel reinforce-ment bars embedded inconcrete.
Test methods to evaluatecorrosivity involve directmeasurement of the amountof acid gas produced during pyrolysis, eg to MIL-DTL-24640 Acid GasGeneration or measurementof pH and electrical con-ductivities of solutions.
Toxicity Index
The various gases given offby combustion of polymericmaterials are toxic to differ-ing degrees.
The Def Stan 02-713,assesses the concentrationof each of the possible by-products and, by measuringthe amounts of these mate-rials, a Toxicity Index isassigned.
Zerohal jacket material hasa typical Toxicity Index of1.7, compared to a typicalvalue of 6 for CSP and 20for PVC jacketed cable. The Def. Standard 61-12
Part 31 specificationrequirement for a cablejacket is <5.
Smoke
The problems of classifyingflammability and corrosivegas generation equallyapply to measuring smokegeneration. The methodaccepted by most authori-ties involves the use of the NBS smoke chamberwhere optical density of the chamber's atmosphereis constantly measured during pyrolysis.
The 10% visibility line indi-cates the density of smokewhich would cause humandisorientation and confu-sion. The rate of change of smoke density can besummarized to a singlenumerical value, as in Def.Standard 02-711, to give asmoke index for a materialand thus offers simple com-parison of materials per-formance.
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Zerohal (Continued)
Cable Jacket Materials
keep the “top weight” to aminimum and since most ofthe equipment is located onthe upper decks, systemweight must be kept as lowas possible.
The diagram shows a light-weight cable compared with a traditional shipboardcable having the samecross-sectional area of cop-per. Both cables have thesame number of conduc-tors. A saving in size hasbeen made on the insula-tion material, but without sacrificing the mechanicalor electrical characteristicsof the cable. A typical saving in cable tray volumecould be as high as 40%.Lightweight cables can also save in excess oftwenty tons on a typicalfrigate and three to five tons on a fast patrol boat.
TE lightweight, small sizecables are giving reliableservice in frigates, corvette's,fast patrol boats, hydrofoilsand submarines in manymajor Navies.
Ships are becoming smallerand more sophisticated,with an ever increasingcomplexity of electronic systems, sensors andweapons. As technologyadvances shipbuilders arecalled upon to update andmodify existing systems orfit completely new ones.The proliferation of elec-tronic hardware requiresmore and more communica-tion systems to transfer datafrom one place to another.To provide all the necessaryinterconnections, hundredsof multicore cables have torun throughout the ship.These, along with cables forpower, lighting and otherbasic services, create asevere space problemwithin ducts and hangers.
For the vessel to achievemaximum speed, maneuver-ability and range, it is vital to
Due to recent improvementsin manufacturing, TE cannow offer an even tightertolerance of ±2.5% on cablediameter. This is well withinthe limits imposed by speci-fications such as Def Stan61-12 part 25, MIL-DTL-24640/24643, and offerssignificant benefits to sys-tem designers, particularlywhere cable glanding isinvolved.
Weight savings within “maxima allowed” by exist-ing specifications are alsoachievable.
Other applications
The increasing awarenessof many areas of industry of the need to minimize firehazard risk is leading to arapid growth in the use ofZerohal jacketed cables.Applications include railand mass transit, offshoreplatforms and otherenclosed areas where a fire would present a significant threat to people or equipment.
Navy Applications
37 Component CableComparison
TE Competition
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-108Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Thermorad HTF/ Fluoroelastomer
Cable Jacket Materials
High TemperaturePerformance Wire andCable Jacket Material
Applications
Thermorad HTF/Fluoroelastomer is a mate-rial specially formulated foruse in applications whereexceptional performance isrequired.
It displays excellent stabilityduring continuous high temperature exposure toadverse chemical environments.
Thermorad HTF/Fluoroelastomer has a con-tinuous operating tempera-
Thermorad HTF/ Fluoroelastomer
Product Factsn High temperature capability
-20°C to +200°C [-4°F to392°F]
n Excellent chemicalresistance
n Flame retardantn Continuous aircraft fuel
immersion
ture of up to 200°C [392°F],and finds applications inaircraft fuel tanks and onhigh performance enginecables. Thermorad HTF/Fluoroelastomer cable jackets are compatible with the Raychem high temperature harnessingsystems — System 200.
System
n System 200
Typical Characteristics when Tested in Accordance with TE Specification WSD 51/1637Tensile strength 12 MPa
Mechanical Elongation 400%Abrasion resistance (1.6 kg load) 40 scrapes min.Cold bend -25°C ± 3°C [-13°F] No crackingHeat age 168 h 250°C [482°F]
Thermal aging Heat shock 4 h at 300°C ± 3°C [572°F] No cracks, drips or flowing,6 mm total shrinkage in 300 mm
Electrical Insulation resistance 20°C [68°F] M ohms. km (min) 10
45° flammability 30 s (max) afterburnOther 100 mm (max) burn length
Vertical flammability Self extinguishing
Available in:
Americas n
Europe n
Asia Pacific n
Wire and Cable
9
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Thermorad/Thermorad F
Cable Jacket Materials
General Purpose Wire andCable Jacket Material
Applications
Thermorad is a general purpose jacket materialwhich is unaffected by mostcommon chemicals and solvents. Thermorad ishighly flame retardant andhas an overall balance ofphysical and chemicalproperties.
Thermorad
Product Factsn Temperature rating -55°C to
+125°C [-67°F to 257°F]n Highly flame retardantn Resistant to fuels, oils and
greasesn UL approved
Thermorad cables findwidespread use in industrial,commercial and militaryapplications. This includesrailways, commercial vehi-cles, medical equipment,communication equipmentand commercial electronics.Thermorad cable jackets arecompatible with Raychempolyolefin tubings, moldedparts and adhesives.
Tensile strength 22 MPa
Mechanical Elongation 400%Abrasion resistance (1.6 kg load) 300 scrapes min.Cold bend -55°C [-67°F]Heat aging 120 h, 170°C [338°F] 60% min. retention of TS and Eb
Thermal aging Heat shock 4 hours at 225°C [437°F] No cracks, drips or flowing,6 mm total shrinkage in 300 mm
72 hour immersion, 50°C [122°F]% Retention of properties
Fluid resistanceTensile strength Elongation
IRM 902 60 60Skydrol® 60 60
Electrical Insulation resistance 20°C [68°F] 20M ohms km (min)
45° flammability 30 s (max.) afterburnOther 75 mm (max.) burn length
Acid gas 4% HCl equivalent (max.)
Typical Characteristics whenTested in Accordance with TESpecification WCD 51/1602(UK) and WCD 3310 (US)
Available in:
Americas n
Europe n
Asia Pacific n
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-110Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Raythane, NT/Thermorad NTFR, Rayolin and AFR
Cable Jacket Materials
Applications
In addition to the preferredcable jacket materials, TE offers a variety ofRaychem cable jackets forspecialized applications.For example, specializedmaterials are available forextreme low temperatureflexibility or for enhancedabrasion resistance, or non-cross-linked materials forcable splicing or overmolding.
Jacket material
Product FactsModified PolyurethanesRaythane Cn -25°C to +80°C
[-13°F to +176°F]and Raythane FRn -65°C to +90°C
[-85°F to +194°F]n Mechanically toughn Can be overmolded
Rayolinn -55°C to +95°C
[-67°F to +203°F]n XL or U-XL are availablen Excellent long term water
immersionn Can be overmoldedn Compatible with TE under-
water cable splices
NT (US designation ThermoradNTFR)n -55°C to +90°C
[-67°F to +194°F]n Extreme flexibilityn Highly flexible at low
temperatures
AFRn -40°C to +105°C
[-40°F to +221°F]n Abrasion resistantn Fuel resistantn Flame retardant
Typical Characteristics when Tested in Accordance with TE Specification WCD
Available in:
Americas n
Europe n
Asia Pacific n
Wire and Cable
9
9-111
NBC
Cable Jacket Materials
Applications
Thermorad 770/780/790Jacket Material for applica-tions requiring NuclearBiological and Chemicalcontamination survivability(NBCCS).
Thermorad 770/780/790 is arevolutionary new fluroelas-tomer material that is resist-ant to nuclear, chemical,and biological threats. Thismaterial has undergonetesting and show resistanceto levels as listed above.
Thermorad 770/780/790cables are ideal for militaryground vehicle applications,communication equipment,and any other equipmentthat may be at risk of expo-sure while in theater.
Product Factsn Temperature rating:
Thermorad 770:-55˚C to 150˚CThermorad 780:-55˚C to 175˚CThermorad 790:-65˚C to 200˚C
n Tested in live agent test withHD, VX and TGD for interiorand exterior exposure
n Tested in accordance withArmy TOP 8-2-510 for NBCcomtamination survivability
n Tested to SC-X15111 andSC-X15112 fluid resistancerequirements for commonlyused military vehicle fluids
n Super Tropical Bleach (STB)and DecontaminationStandard #2 (DS2), wereused per TOP 8-2-511 todecontaminate specimens atinterior (1 g/m2) and exterior(10 g/m2) exposure levels,respectively
They are ideal for use inNBC decontamination sta-tions. Thermorad770/780/790 jackets arecompatible with TERaychem brand tubing and molded parts.
System
System 700
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9-112Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
NBC (Continued)
Cable Jacket Materials
Typical Characteristics when Tested in Accordance with:RT 770 RT 780 RT 790Thermorad 770 Thermorad 780 Thermorad 790
In many applications,shielding of cables is important, whether it be to minimize cross-talk within the cable, to preventinterference from externalsources, or to eliminate radiation from the cableitself.
The design of cables to provide effective shieldingover a broad frequencyspectrum is complex, andcables must be tailored to
specific electromagneticenvironments. From simplealuminized polyester filmthat provides electrostaticshielding to progressivelymore complex shielding that can be designed incorporating plated copperbraids and Mu metal wraps.
Optimization
Performance of conven-tional braiding can be significantly improved bycomputer optimization. This tightly controlled
process can give many times the shielding performance of a basicbraided shield with minimalweight penalty or increasein optical coverage.Supershielded cables combine Mu metal wrapswith optimized braids toprovide even further enhanced performance,especially at low frequencies.
Available in:Americas n
Europe n
Asia Pacific n
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Miscellaneous
Electrical Shielding (Continued)
Measuring ShieldingEfficiencySurface Transfer Impedance (Zt)
To assess the effectivenessof a shield, TE has adoptedthe line injection method asdescribed in IEC 1196-1 to measure the surfacetransfer impedance (Zt) of acable shield. This relates theopen circuit voltage gener-ated on a component wireinside the cable to the currentinjected on the overallshield. The unit of Zt isOhms per meter, thus thevoltage coupling is lengthdependent and long cablesexhibit more leakage thansimilar but shorter lengthones. To determine the surface transfer impedanceacross a range of frequen-cies, a drive signal is gener-ated by the internal trackinggenerator of a spectrumanalyzer, and amplified. Thevoltage is induced on thecenter conductor of thesample which is amplifiedand returned to the signalgenerator for measurement.The understanding of leakage mechanisms hasenabled TE to designcables with guaranteed minimum Zt values for thedesired operating environ-ment.
SupershieldingEMP Hardened Cables
The requirements fornuclear hardened cablespresent the engineer with a range of problems. Thewaveform of the EMP issuch that the majority ofpower is dissipated in a frequency band between 1 KHz and 5 MHz, where littleprotection is given by con-ventionally shielded cables.TE has solved this problemwith a range of super-
Design and ManufacturingExpertise
The problems of shieldingcables are complex.However, with the introduc-tion of optimized braids andsupershielded cables, TEhas the capability to solvethe most difficult shieldingproblems. Shielding ofcables without degradingcable flexibility can be pro-vided for coaxial and multi-conductor cables for allEMC and EMP conditions.To complement this rangeof cables, TE manufacturesRaychem cable termina-tions and connector backfittings to give total intercon-nection system shieldingperformance.
shielded cables which giveshielding performance atthese frequencies by incor-porating materials whichchange the inductance ofthe shield and lower thetransfer impedance. TEsupershielded cables havea sandwich construction ofMu metal tapes betweenoptimized braids. Mu metalis a ferro-magnetic materialwhich has a high perme-ability over a wide range offield strengths. It is appliedto the cable in a way whichmaintains cable flexibilityand minimizes work harden-ing and any consequentreduction in permeability.Supershielded cables notonly give protection againstEMP but also other majorinterference modes.
Shielded CablesControlling the Threat
Testing
TE EMC test facilities havethe capability for bulk current injection testing inaddition to surface transferimpedance measurements.The installation is a provenfacility in characterizingnew design parameters.
100
10
1
0.1
0.01
0.001
0.0001
103 104 105 106 107 108
Screening performanceof various types of screen constructions
55
65
75
85
95
105
115
125
135
145
155
165
175
EM
Shielding effectiveness (dB
/meter)
Frequency (Hz)
Sur
face
tran
sfer
impe
danc
e(m
.ohm
s/m
eter
)
AluminizedPolyester
SingleStranded Braid
SingleOptimized
DoubleOptimized
SingleSuperscreen
SolidCopper screen
DoubleSuperscreen
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9Wire and Cable
9-115
Miscellaneous
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Applications
TE offers a range of flexibleRaychem power cables thatare insulated and jacketedusing materials that provideimproved performance overother materials, such asCSP/EPR, silicone, orPCP/Butyl. Five differenttypes of cable are available:
Type TR is a general purpose, single-wall, 125°C [257°F] constructionnormally specified for useinside cabinets in protectedareas.
Type ZHI is a halogen-free105°C [221°F] cable withgood oil resistance. It isparticularly suitable for usein offshore, ship, and masstransit applications wherelow-fire-hazard performanceis required. Refer to TEspecification WCD 2015.
Type AFR is a 105°C[221°F], single-extrusion,abrasion-resistant, flame-and fuel-resistant,radiation-crosslinked polyolefin.
Type FTR is a dual-wall,125°C [257°F], diesel-oil-resistant cable originallydeveloped for tank enginecompartment applications.It meets the German BWBVG 95218 specification.Refer to TE specificationWCD 2002. (US AlternativeType 10603)
Type ZHPCG is a halogen-free, 115°C [239°F] cablewith good oil resistance and resistance to water. It is particularly suitable tothe Mass Transit, Marineand Off-Shore industrieswhere its low fire hazard performance and flexibilityare key to a successfulinstallation. Refer to TESpecification WSD 1265.(US Alternative Type2HPC06XT and 2HPC20XT)
Type 80 Flexible LightWeight Aluminum PowerFeeders are designed witha dual wall flexible ETFE(±175˚C) insulation basedsystem to allow the cable tobe bent and routed inextremely tight areas withno wrinkling or cracking ofthe insulation. The designhas been tested to verify
Product Factsn Choice of jacket materialsn -65°C to +260°C
[-85°F to +500°F]n Size and weight savingsn Excellent flexibilityn Resistance to solvents and
chemicalsn Corona resistancen Increased flexibility in
installationn Arc-resistance of materials
that it meets key aerospaceindustry requirements offlexibility, corona resistanceand wrinkling in high volt-age applications. TE alsohas the facilities to testcorona resistance or pro-duction wire and cable at400 Hz and various altitudes. (Contact TE formore information)
Type Superflex is a 260˚Crated fluoropolymer insula-tion based system. Theneed for a combination ofhigh temperature and highperformance in wire insula-tion has become a criticalfactor in today’s platforms.This is especially true inlarge diameter powerfeeder applications wheretemperature and durabilityare key. TE new product lineoffering comes rated at200˚C for 10 K hours. (Contact TE for more information)
Available in:Americas n
Europe n
Asia Pacific n
Power Cables
Each power cable offersparticular advantages forspecific applications and isalso available in multicon-ductor constructions andshielded and jacketed versions. Cables offer sizeand weight savings, goodresistance to abrasion andcut-through, and the abilityto operate in difficult environments.
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Miscellaneous
Specifications/Approvals*Series Military TETR — WCD 2003, WSD51/1602ZHI Def. Standard 61-12 Part 31 (jacket material) WSD 2015FTR BWB VG 95218 Types G, H, and K WSD 2002AFR — WCD 2011, WSD51/1619ZHPCG — WSD 126580 — SPEC 80
Superflex — WCD 3111
*See specifications listed for details of performance.
Conductors (Tinned Soft Copper)Stranding
Conductor Size IEC Class 5 IEC Class 6 Max. Resistance at 20°C in Ω/km (Ω/1000 ft)mm2
*For Type 80 and Superflex, contact TE for conductor details.
Materials Performance SummaryTensile Temperature
Material Strength Abrasion Cut Through Rating °C Preferred
N/mm2 typical Resistance 10000 h Color
TR 20 Excellent Good 125 BlackZHI 9 Good Very Good 105 BlackFTR 18 Good Good 125 BlackAFR 18 Excellent Very Good 105 GreyZHPCG 9 Good Good 115 Black80 -21 Very Good Very Good 175 White
Supeflex -14 Very Good Very Good 260 White
Note: Where a higher operating temperature is required, TE SPEC 55 wire provides outstanding performance up to 200°C continuous operating temperature.For these or other special applications, please contact TE.
Power Cables (Continued)
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
9Wire and Cable
9-117
Miscellaneous
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Catalog 1654025 Dimensions are shown for Dimensions are in millimeters USA: +1 800 522 6752 For additional support numbersRevised 3-13 reference purposes only. unless otherwise specified. Asia Pacific: +86 0 400 820 6015 please visit www.te.com
Specifications subject UK: +44 800 267 666www.te.com to change.
Table 1. Nominal Diameters and Maximum WeightsTR 16 FTR 16
ConductorNom. OD Max. weight in Nom. OD Max. weight inSize (mm2) Part No.in mm (in) kg/km (lb/1000 ft)